Methods and apparatuses for making elastomeric laminates

ABSTRACT

The present disclosure relates to methods for making elastomeric laminates that may be used as components of absorbent articles. Aspects of the methods for assembling elastomeric laminates may utilize elastic strands supplied from beams that may be joined with first and second substrates, and may be configured to carry out various types of operations, such as bonding and splicing operations.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.17/474,423, filed on Sep. 14, 2021, which is a continuation of U.S.application Ser. No. 15/839,896, filed on Dec. 13, 2017, which claimsthe benefit of U.S. Provisional Application No. 62/436,589, filed onDec. 20, 2016; 62/483,965, filed on Apr. 11, 2017; 62/553,538, filed onSep. 1, 2017; 62/553,149, filed on Sep. 1, 2017; 62/553,171, filed onSep. 1, 2017; and 62/581,278, filed on Nov. 3, 2017, the entireties ofwhich are all incorporated by reference herein.

FIELD OF THE INVENTION

The present disclosure relates to methods for manufacturing absorbentarticles, and more particularly, to apparatuses and methods for makingelastomeric laminates that may be used as components of absorbentarticles.

BACKGROUND OF THE INVENTION

Along an assembly line, various types of articles, such as for example,diapers and other absorbent articles, may be assembled by addingcomponents to and/or otherwise modifying an advancing, continuous web ofmaterial. For example, in some processes, advancing webs of material arecombined with other advancing webs of material. In other examples,individual components created from advancing webs of material arecombined with advancing webs of material, which in turn, are thencombined with other advancing webs of material. In some cases,individual components created from an advancing web or webs are combinedwith other individual components created from other advancing webs. Websof material and component parts used to manufacture diapers may include:backsheets, topsheets, leg cuffs, waist bands, absorbent corecomponents, front and/or back ears, fastening components, and varioustypes of elastic webs and components such as leg elastics, barrier legcuff elastics, stretch side panels, and waist elastics. Once the desiredcomponent parts are assembled, the advancing web(s) and component partsare subjected to a final knife cut to separate the web(s) into discretediapers or other absorbent articles.

Some absorbent articles have components that include elastomericlaminates. Such elastomeric laminates may include an elastic materialbonded to one or more nonwovens. The elastic material may include anelastic film and/or elastic strands. In some laminates, a plurality ofelastic strands are joined to a nonwoven while the plurality of strandsare in a stretched condition so that when the elastic strands relax, thenonwoven gathers between the locations where the nonwoven is bonded tothe elastic strands, and in turn, forms corrugations. The resultingelastomeric laminate is stretchable to the extent that the corrugationsallow the elastic strands to elongate.

In some assembly processes, stretched elastic strands may be advanced ina machine direction and may be adhered between two advancing substrates,wherein the stretched elastic strands are spaced apart from each otherin a cross direction. Some assembly processes are also configured withseveral elastic strands that are very closely spaced apart from eachother in the cross direction. In some configurations, close crossdirectional spacing between elastic strands can be achieved by drawingelastic strands from windings that have been stacked in the crossdirection on a beam. For example, various textile manufacturers mayutilize beam elastics and associated handling equipment, such asavailable from Karl Mayer Corporation. However, problems can beencountered in manufacturing processes when drawing elastic strandsstacked on a beam.

For example, relatively low decitex elastic strands supplied on a beammay include a coating, sometimes referred to a yarn finish or spinfinish, to help prevent the elastics strands from adhering tothemselves, each other, and/or downstream handling equipment. Whenconstructing absorbent articles, hot melt adhesives are sometimes usedto adhere stretched elastic stands to advancing substrates to createelastic laminates. However, hot melt adhesives used to adhere stretchedelastic strands to substrates when constructing absorbent articles maynot adhere well to strands having a spin finish. As such, increasedamounts of adhesive may be required to adequately adhere the stretchedelastic strands to the substrates than would otherwise be required forelastic stands without a spin finish. In turn, relatively larger amountsof adhesives required to bond the elastic strands to the substrates mayhave a negative impact on aspects of the resulting product, such as withrespect to costs, functionality, and aesthetics.

Consequently, it may be beneficial to provide methods and apparatusesfor producing elastomeric laminates by removing or substantiallyremoving the spin finish from elastic strands unwound from beams beforeadhering the elastic strands to advancing substrates. It may also bebeneficial to provide methods and apparatuses for producing elastomericlaminates by bonding elastic strands with a spin finish to substrateswithout having to apply relatively large amounts of adhesive along theentire lengths of the elastic strands.

In an attempt to overcome the aforementioned problems associated withadhesives, some assembly processes may be configured to apply mechanicalbonds with heat and pressure to trap the stretched elastic strandsbetween two substrates. Such mechanical bonds may be created, forexample, by advancing the substrates and elastic strands between anultrasonic horn and anvil. However, the heat and pressure from the anviland horn may also sever the elastic strands. As such, grooves may beprovided in the horn or anvil for the elastic strands to nest in and toshield the elastic strands from pressure and prevent severing throughthe bonding process, such as disclosed in U.S. Pat. No. 6,291,039 andEuropean Patent Publication No. EP 3 092 997 B1. However, positioninghundreds of elastic strands drawn from a beam in nesting grooves on anultrasonic horn and/or anvil may add complexity to the assembly process.

Consequently, it would be beneficial to provide methods and apparatusesfor producing elastomeric laminates by mechanically bonding elasticstrands between substrates without severing the elastics strands, and/orwithout the need for having to guide elastic strands into designatednesting grooves in a mechanical bonding device.

In some absorbent article assembly operations, the elasticity of regionsof an elastomeric laminate may be removed or deactivated by cuttingelastic strands in the regions. For example, some diaper pantembodiments are configured with an absorbent chassis connected withfront and back elastic belts, wherein opposing end regions of the frontand back belts are connected with each other at side seams. In someconfigurations, diaper pants may include graphics in certain regions ofthe belts connect with the absorbent chassis, and the absence ofelasticity in such regions may allow for reduced distortion of graphicslocated in those regions. As such, the elasticity of the front and backbelts may be removed in regions where the absorbent chassis connectswith the belts. Thus, in some converting configurations adapted toassemble such diaper pants, stretched elastic strands are bonded betweentwo continuous nonwoven webs to form an elastomeric laminate. Regions ofthe elastic strands may then be intermittently deactivated along thelength of the elastomeric laminate by cutting the elastic strands.Subsequent to deactivating the elastic strands, the elastomeric laminatemay be subjected to additional handling and converting operations.

As previously mentioned, in some manufacturing configurations, hot meltadhesives are used to adhere stretched elastic stands to advancingsubstrates to create elastomeric laminates. However, in attempts toeliminate and reduce the costs and complexities associated with the useof adhesives, some assembly processes may be configured to applymechanical bonds with heat and pressure to trap the stretched elasticstrands between two substrates.

However, utilizing mechanical bonding techniques to create elastomericlaminates with unbonded regions and subsequently cutting stretchedelastic strands in the unbonded regions to create deactivated regions inthe elastomeric laminates may present certain challenges. For example,the ends of the cut elastic stands may snap back in an uncontrolledfashion and consequently may end up in undesired locations within theelastomeric laminate. In some instances, ends of cut elastic strands mayform of a lump of elastic material within the elastomeric laminate,which may negatively impact comfort and appearance of an assembledproduct.

Consequently, it may be beneficial to provide methods and apparatusesthat are configured to assemble elastomeric laminates in such a way tomaximize the aesthetic appearance of such laminates when placed in anassembled product and/or reduce handling of the elastomeric laminatesafter mechanically bonding the elastics therein.

Other problems can be encountered in manufacturing processes whendrawing elastic strands stacked on a beam. For example, when elasticstrands are completely drawn from the beam, a new beam of elastics willbe needed to replace the empty beam. As such, in some configurations, anentire manufacturing line may need to be temporarily stopped while theempty beam is replaced. Manufacturing lines in the textile industryoften operate at relatively slow speeds, and as such, these textilemanufacturing lines can be temporarily stopped to replace an empty beamand may not result in a major disruption to production. However, somemanufacturing lines, such as disposable absorbent article manufacturinglines, may operate at high speeds and/or would require depleted beams ofelastics to be replaced relatively often. As such, it can be inefficientand/or cost prohibitive to frequently stop and restart high speedmanufacturing operations to replace empty beams.

Consequently, it may be beneficial to provide a method and apparatus forproducing elastomeric laminates with beams of elastic strands that canbe replaced without having to stop the assembly process.

SUMMARY OF THE INVENTION

In one form, a method for making absorbent articles comprises: providingelastic strands wound onto a beam; rotating the beam to unwind theelastic strands from the beam; advancing the elastic strands from therotating beam; stretching the elastic strands; and bonding the stretchedelastic strands between a first substrate and a second substrate to forman elastomeric laminate.

In another form, a method for making an elastomeric laminate comprises:providing first elastic strands wound onto a first beam, wherein atleast one of the first elastic strands comprises a spin finish;providing second elastic strands; unwinding the first elastic strandsfrom the first beam; advancing a first substrate and a second substratein a machine direction; stretching the first and second elastic strands;and bonding the stretched first elastic strands and the second elasticstrands with and between the first substrate and the second substrate toform an elastomeric laminate, wherein the elastomeric laminate comprisesa first region having a first stretch characteristic defined by thefirst elastic strands and a second region having a second stretchcharacteristic defined by the second elastic strands, wherein the firststretch characteristic is different from the second stretchcharacteristic.

In yet another form, a method for making an elastomeric laminatecomprises: providing elastic strands wound onto a beam, wherein theelastic strands comprise a spin finish; rotating the beam to unwind theelastic strands from the beam; advancing the elastic strands from therotating beam; stretching the elastic strands; bonding discrete lengthsof the stretched elastic strands with and between a first substrate anda second substrate with discrete first bonds arranged intermittentlyalong a machine direction; and applying second bonds extending in themachine direction between consecutive first bonds to bond the first andsecond substrates directly to each other.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a front perspective view of a diaper pant.

FIG. 1B is a rear perspective view of a diaper pant.

FIG. 2 is a partially cut away plan view of the diaper pant shown inFIGS. 1A and 1B in a flat, uncontracted state.

FIG. 3A is a cross-sectional view of the diaper pant of FIG. 2 takenalong line 3A-3A.

FIG. 3B is a cross-sectional view of the diaper pant of FIG. 2 takenalong line 3B-3B.

FIG. 4 shows an example of an empty beam having two side platesconnected with opposing end portions of a mandrel core and illustrates aview of the converting apparatus of FIG. 57 taken along line 4-4.

FIG. 5 is a schematic side view of a converting apparatus including adetergent bath adapted to remove a spin finish from a plurality ofelastic strands before being adhered between a first substrate and asecond substrate.

FIG. 6 is a view of the converting apparatus of FIG. 5 taken along line6-6.

FIG. 7 is a schematic side view of a converting apparatus including adetergent spray and wiper adapted to remove a spin finish from aplurality of elastic strands before being adhered between a firstsubstrate and a second substrate.

FIG. 8 is a schematic side view of a converting apparatus wherein afirst substrate is configured to wipe a spin finish from a plurality ofelastic strands before being adhered between the first substrate and asecond substrate.

FIG. 9 is a schematic side view of another configuration of a convertingapparatus adapted to manufacture an elastomeric laminate including aspin finish removal apparatus.

FIG. 10 is a schematic side view of another configuration of aconverting apparatus adapted to manufacture an elastomeric laminateincluding a spin finish removal apparatus.

FIG. 11 is a schematic side view of another configuration of aconverting apparatus adapted to manufacture an elastomeric laminateincluding a spin finish removal apparatus.

FIG. 12 is a schematic side view of a converting apparatus joiningstretched elastic strands having a spin finish between a first substrateand a second substrate, wherein first and second bonds are applied tothe first substrate before joining the first and second substrates withthe elastics strands.

FIG. 13 is a view of the converting apparatus and elastic laminate ofFIG. 12 taken along line 13-13.

FIG. 13A is a view of the converting apparatus of FIG. 13 showing analternative configuration of second bonds extending contiguously in thecross direction CD between and across elastic strands.

FIG. 14 is a view of the first substrate of FIGS. 12, 18, and 21 takenalong line 14-14.

FIG. 15 is a view of the first substrate of FIG. 12 taken along line15-15.

FIG. 16A shows a length of an elastic strand in a relaxed state with afirst cross sectional area.

FIG. 16B shows a length of the elastic strand of FIG. 16A in a stretchedstate with a second cross sectional area that is less than the firstcross sectional area.

FIG. 17A is a detailed view of a stretched elastic strand positionedbetween the second bonds.

FIG. 17B is a detailed view of a contracted elastic strand havingportions immobilized between the second bonds.

FIG. 18 is a schematic side view of another configuration of aconverting apparatus joining elastic strands having a spin finishbetween a first substrate and a second substrate, wherein first bondsare applied before joining the strands with the first and secondsubstrates and second bonds are applied after joining the strands withthe first and second substrates.

FIG. 19 is a view of the elastic laminate of FIG. 18 taken along line19-19.

FIG. 20 is a view of the elastic laminate of FIG. 18 taken along line20-20.

FIG. 21 is a schematic side view of another configuration of aconverting apparatus joining elastic strands having a spin finishbetween a first substrate and a second substrate, wherein the elasticstrands are drawn from different beams.

FIG. 22 is a view of the converting apparatus of FIG. 21 taken alongline 22-22.

FIG. 23 is a schematic side view of another configuration of aconverting apparatus adapted to manufacture an elastomeric laminateincluding first and second bonds.

FIG. 24 is a schematic side view of another configuration of aconverting apparatus adapted to manufacture an elastomeric laminateincluding first and second bonds.

FIG. 25 is a schematic illustration of a diaper pant assembly processwith elastomeric laminates.

FIG. 26 is a schematic side view of a converting apparatus joiningstretched elastic strands between a first substrate and a secondsubstrate.

FIG. 26A is a detailed view of an example bonding apparatus configuredwith an anvil and ultrasonic horn.

FIG. 27 is a view of the converting apparatus of FIG. 26 taken alongline 27-27.

FIG. 28A is a detailed view of an elastic strand in a stretched statebonded between the first and second substrates.

FIG. 28B is a detailed view of an elastic strand in a relaxed statebonded between the first and second substrates.

FIG. 29A is a sectional view of the elastic strand, bond, firstsubstrate, and second substrate of FIG. 28A taken along line 29A-29A.

FIG. 29B is a sectional view of the elastic strand in a bonded region ofFIG. 28B taken along line 29B-29B, wherein the elastic strand is in arelaxed state.

FIG. 29C is a sectional view of the elastic strand in an unbonded regionof FIG. 28B taken along line 29C-29C, wherein the elastic strand is in arelaxed state.

FIG. 30A is a sectional view of an elastic strand, bond, firstsubstrate, and second substrate of FIG. 28A taken along line 29A-29A,wherein a plurality of filaments of the elastic strand are bonded in afirst configuration.

FIG. 30B is a sectional view of an elastic strand, bond, firstsubstrate, and second substrate of FIG. 28A taken along line 29A-29A,wherein a plurality of filaments of the elastic strand are bonded in asecond configuration.

FIG. 30C is a sectional view of an elastic strand, bond, firstsubstrate, and second substrate of FIG. 28A taken along line 29A-29A,wherein a plurality of filaments of the elastic strand are bonded in athird configuration.

FIG. 30D is a scanning electron microscope (“SEM”) photograph of a crosssectional view of an elastic strand including five filaments in a bondedregion and surrounded by hardened first and second materials.

FIG. 30E is a scanning electron microscope (“SEM”) photograph of a crosssectional view of an elastic strand including five filaments in a bondedregion and surrounded by hardened first and second materials.

FIG. 30F is a scanning electron microscope (“SEM”) photograph of a crosssectional view of an elastic strand including fifteen filaments in abonded region and surrounded by hardened first and second materials.

FIG. 31 is a schematic side view of another configuration of aconverting apparatus joining elastic strands between a first substrateand a second substrate, wherein the elastic strands drawn from differentbeams are stretched to have different elongations.

FIG. 32 is a view of the converting apparatus of FIG. 31 taken alongline 32-32.

FIG. 33 is a schematic side view of another configuration of aconverting apparatus adapted to manufacture an elastomeric laminate.

FIG. 34 is a schematic side view of another configuration of aconverting apparatus adapted to manufacture an elastomeric laminate.

FIG. 35 is a schematic side view of another configuration of aconverting apparatus adapted to manufacture an elastomeric laminate.

FIG. 36 is a view of the converting apparatus of FIG. 35 taken alongline 36-36.

FIG. 37 is a view of the converting apparatus of FIG. 44 taken alongline 37-37.

FIG. 38 is a schematic side view of a converting apparatus joiningstretched elastic strands between a first substrate and a secondsubstrate.

FIG. 38A is a schematic side view of a converting apparatus with abonding apparatus configured with an anvil.

FIG. 38B is a schematic side view of a converting apparatus with abonding apparatus configured with a cutting roll adapted to engage thepattern roll.

FIG. 39 is a view of the converting apparatus of FIG. 38 taken alongline 39-39.

FIG. 39A is a detailed cross sectional view of the elastomeric laminateadvancing through the nip between the pattern roll and the pressingsurface showing an elastic strand extending through a channel.

FIG. 40 is a detailed view of an example pattern roll with pluralitiesof bonding surfaces and a protuberance.

FIG. 41 is a view of an outer circumferential surface of a pattern rolllaid out flat and showing pluralities of bonding surfaces and aprotuberance.

FIG. 41A is a view of an outer circumferential surface of a pattern rolllaid out flat and showing a protuberance configured as a plurality ofdiscrete members.

FIG. 42A is a sectional view of a first channel on the pattern roll ofFIG. 41 taken along line 42A-42A.

FIG. 42B is a sectional view of a second channel on the pattern roll ofFIG. 41 taken along line 42B-42B.

FIG. 42C is a sectional view of a protuberance on the pattern roll ofFIG. 41 taken along line 42C-42C.

FIG. 43A is a detailed view of an elastic strand in a stretched statebonded between the first and second substrates.

FIG. 43B is a detailed view of an elastic strand in a relaxed statebonded between the first and second substrates.

FIG. 44A is a sectional view of the elastic strand, bonds, firstsubstrate, and second substrate of FIG. 43A taken along line 44A-44A.

FIG. 44B is a sectional view of the elastic strand, bonds, firstsubstrate, and second substrate of FIG. 43B taken along line 44B-44B.

FIG. 44C is a sectional view of an elastic strand, bond, firstsubstrate, and second substrate, wherein a plurality of filaments of theelastic strand are bonded in a first configuration.

FIG. 44D is a sectional view of an elastic strand, bond, firstsubstrate, and second substrate, wherein a plurality of filaments of theelastic strand are bonded in a second configuration.

FIG. 45A shows a detailed view of an elastomeric laminate from FIGS. 38and 39 advancing from the nip between the pattern roll and pressingsurface with the first substrate cut-away to illustrate example bondconfigurations and stretched elastic strands.

FIG. 45B shows a detailed view of an elastomeric laminate from FIG. 45Acontinuing to advance from the nip between the pattern roll and pressingsurface to illustrate stretched elastic strands having been severedbetween the protuberance and the pressing surface.

FIG. 45C shows a detailed view of an elastomeric laminate from FIG. 45Bcontinuing to advance from the nip between the pattern roll and pressingsurface to illustrate retracting elastic strands after having beensevered.

FIG. 45D shows a detailed view of an elastomeric laminate from FIG. 45Ccontinuing to advance from the nip between the pattern roll and pressingsurface to illustrate additional bonds having been applied.

FIG. 45E shows a detailed view of an elastomeric laminate from FIG. 45Dcontinuing to advance from the nip between the pattern roll and pressingsurface to illustrate severed elastic strands having retracted to bondregions to define a deactivated region of the elastomeric laminate.

FIG. 46A shows a detailed view of an elastomeric laminate illustratingsevered elastic strands having retracted to bond regions and showingexamples of discrete bonds created by the protuberance in thedeactivated region of the elastomeric laminate.

FIG. 46B shows a detailed view of an elastomeric laminate illustratingsevered elastic strands having been cut into discrete pieces in thedeactivated region of the elastomeric laminate.

FIG. 47 is a schematic side view of an additional configuration of aconverting apparatus adapted to manufacture an elastomeric laminate.

FIG. 48 is a view of the converting apparatus of FIG. 47 taken alongline 48-48.

FIG. 49 is a view of the converting apparatus of FIG. 47 taken alongline 48-48.

FIG. 50 is a detailed view of an example pattern roll with pluralitiesof bonding surfaces and a protuberance.

FIG. 51 is a view of an outer circumferential surface of a pattern rolllaid out flat and showing pluralities of bonding surfaces and aprotuberance.

FIG. 52 is a sectional view of a pattern surface and a protuberance onthe pattern roll of FIG. 51 taken along line 52-52.

FIG. 53 is a schematic side view of a converting apparatus adapted tomanufacture an elastomeric laminate including a first plurality ofelastic strands positioned between a first substrate and a secondsubstrate.

FIG. 54 is a view of the converting apparatus of FIG. 53 taken alongline 54-54.

FIG. 55 is a view of the converting apparatus of FIG. 53 taken alongline 55-55.

FIG. 56 is a schematic side view of the converting apparatus of FIG. 53showing a second plurality of elastic strands connected with a firstplurality of elastic strands upstream of a nip.

FIG. 57 is a schematic side view of the converting apparatus of FIG. 53showing the first and second plurality of elastic strands advancingthrough the nip.

FIG. 58 is a view of the converting apparatus of FIG. 57 taken alongline 58-58.

FIG. 59 is a schematic side view of the converting apparatus of FIG. 53assembling the elastomeric laminate with the second plurality of elasticstrands positioned between the first and second substrates.

FIG. 60 is a view of the converting apparatus of FIG. 59 taken alongline 60-60.

FIG. 61 is a schematic side view of the converting apparatus of FIG. 53showing the second plurality of elastic strands connected with the firstsubstrate upstream of a nip.

FIG. 62 is a schematic side view of another configuration of aconverting apparatus adapted to manufacture an elastomeric laminateincluding a first plurality of elastic strands positioned between afirst substrate and a second substrate.

FIG. 63 is a schematic side view of the converting apparatus of FIG. 62showing a second plurality of elastic strands connected with a firstplurality of elastic strands upstream of a first roller.

FIG. 64 is a schematic side view of the converting apparatus of FIG. 62showing the first and second plurality of elastic strands advancing ontothe first substrate.

FIG. 65 is a schematic side view of the converting apparatus of FIG. 62assembling the elastomeric laminate with the second plurality of elasticstrands positioned between the first and second substrates.

FIG. 66 is a schematic side view of the converting apparatus of FIG. 62showing the second plurality of elastic strands connected with the firstsubstrate upstream of the first roller.

FIG. 67 is a schematic side view of another configuration of aconverting apparatus adapted to manufacture an elastomeric laminateincluding a first plurality of elastic strands positioned between afirst substrate and a second substrate.

FIG. 68 is a schematic side view of the converting apparatus of FIG. 67assembling the elastomeric laminate with the first and second pluralityof elastic strands advancing between the first and second substrates.

FIG. 69 is a schematic side view of the converting apparatus of FIG. 67assembling the elastomeric laminate showing the trailing ends of thefirst plurality of elastic strands advancing between the first andsecond substrates.

FIG. 70 is a schematic side view of the converting apparatus of FIG. 67assembling the elastomeric laminate with the second plurality of elasticstrands positioned between the first and second substrates.

DETAILED DESCRIPTION OF THE INVENTION

The following term explanations may be useful in understanding thepresent disclosure: “Absorbent article” is used herein to refer toconsumer products whose primary function is to absorb and retain soilsand wastes. Absorbent articles can comprise sanitary napkins, tampons,panty liners, interlabial devices, wound dressings, wipes, disposablediapers including taped diapers and diaper pants, inserts for diaperswith a reusable outer cover, adult incontinent diapers, adultincontinent pads, and adult incontinent pants. The term “disposable” isused herein to describe absorbent articles which generally are notintended to be laundered or otherwise restored or reused as an absorbentarticle (e.g., they are intended to be discarded after a single use andmay also be configured to be recycled, composted or otherwise disposedof in an environmentally compatible manner).

An “elastic,” “elastomer” or “elastomeric” refers to materialsexhibiting elastic properties, which include any material that uponapplication of a force to its relaxed, initial length can stretch orelongate to an elongated length more than 10% greater than its initiallength and will substantially recover back to about its initial lengthupon release of the applied force.

As used herein, the term “joined” encompasses configurations whereby anelement is directly secured to another element by affixing the elementdirectly to the other element, and configurations whereby an element isindirectly secured to another element by affixing the element tointermediate member(s) which in turn are affixed to the other element.

The term “substrate” is used herein to describe a material which isprimarily two-dimensional (i.e. in an XY plane) and whose thickness (ina Z direction) is relatively small (i.e. 1/10 or less) in comparison toits length (in an X direction) and width (in a Y direction).Non-limiting examples of substrates include a web, layer or layers orfibrous materials, nonwovens, films and foils such as polymeric films ormetallic foils. These materials may be used alone or may comprise two ormore layers laminated together. As such, a web is a substrate.

The term “nonwoven” refers herein to a material made from continuous(long) filaments (fibers) and/or discontinuous (short) filaments(fibers) by processes such as spunbonding, meltblowing, carding, and thelike. Nonwovens do not have a woven or knitted filament pattern.

The term “machine direction” (MD) is used herein to refer to thedirection of material flow through a process. In addition, relativeplacement and movement of material can be described as flowing in themachine direction through a process from upstream in the process todownstream in the process.

The term “cross direction” (CD) is used herein to refer to a directionthat is generally perpendicular to the machine direction.

The term “taped diaper” (also referred to as “open diaper”) refers todisposable absorbent articles having an initial front waist region andan initial back waist region that are not fastened, pre-fastened, orconnected to each other as packaged, prior to being applied to thewearer. A taped diaper may be folded about the lateral centerline withthe interior of one waist region in surface to surface contact with theinterior of the opposing waist region without fastening or joining thewaist regions together. Example taped diapers are disclosed in varioussuitable configurations U.S. Pat. Nos. 5,167,897, 5,360,420, 5,599,335,5,643,588, 5,674,216, 5,702,551, 5,968,025, 6,107,537, 6,118,041,6,153,209, 6,410,129, 6,426,444, 6,586,652, 6,627,787, 6,617,016,6,825,393, and 6,861,571; and U.S. Patent Publication Nos. 2013/0072887A1; 2013/0211356 A1; and 2013/0306226 A1, all of which are incorporatedby reference herein.

The term “pant” (also referred to as “training pant”, “pre-closeddiaper”, “diaper pant”, “pant diaper”, and “pull-on diaper”) refersherein to disposable absorbent articles having a continuous perimeterwaist opening and continuous perimeter leg openings designed for infantor adult wearers. A pant can be configured with a continuous or closedwaist opening and at least one continuous, closed, leg opening prior tothe article being applied to the wearer. A pant can be preformed orpre-fastened by various techniques including, but not limited to,joining together portions of the article using any refastenable and/orpermanent closure member (e.g., seams, heat bonds, pressure welds,adhesives, cohesive bonds, mechanical fasteners, etc.). A pant can bepreformed anywhere along the circumference of the article in the waistregion (e.g., side fastened or seamed, front waist fastened or seamed,rear waist fastened or seamed). Example diaper pants in variousconfigurations are disclosed in U.S. Pat. Nos. 4,940,464; 5,092,861;5,246,433; 5,569,234; 5,897,545; 5,957,908; 6,120,487; 6,120,489;7,569,039 and U.S. Patent Publication Nos. 2003/0233082 A1; 2005/0107764A1, 2012/0061016 A1, 2012/0061015 A1; 2013/0255861 A1; 2013/0255862 A1;2013/0255863 A1; 2013/0255864 A1; and 2013/0255865 A1, all of which areincorporated by reference herein.

The present disclosure relates to methods for manufacturing absorbentarticles, and in particular, to methods for making elastomeric laminatesthat may be used as components of absorbent articles. The elastomericlaminates may include a first substrate, a second substrate, and anelastic material located between the first substrate and secondsubstrate. During the process of making the elastomeric laminate, theelastic material may be advanced and stretched in a machine directionand may be joined with either or both the first and second substratesadvancing in the machine direction. The elastomeric laminates madeaccording to the processes and apparatuses discussed herein may be usedto construct various types of components used in the manufacture ofdifferent types of absorbent articles, such as diaper pants and tapeddiapers, such as for example disclosed in U.S. Patent Application No.62/553,538, filed on Sep. 1, 2017. To help provide additional context tothe subsequent discussion of the process embodiments, the followingprovides a general description of absorbent articles in the form ofdiapers that include components including the elastomeric laminates thatmay be produced with the methods and apparatuses disclosed herein.

FIGS. 1A, 1B, and 2 show an example of an absorbent article 100 in theform of a diaper pant 100P that may include components constructed fromelastomeric laminates assembled in accordance with the apparatuses andmethods disclosed herein. In particular, FIGS. 1A and 1B showperspective views of a diaper pant 100P in a pre-fastened configuration,and FIG. 2 shows a plan view of the diaper pant 100P with the portion ofthe diaper that faces away from a wearer oriented toward the viewer. Thediaper pant 100P includes a chassis 102 and a ring-like elastic belt104. As discussed below in more detail, a first elastic belt 106 and asecond elastic belt 108 are bonded together to form the ring-likeelastic belt 104.

With continued reference to FIG. 2 , the diaper pant 100P and thechassis 102 each include a first waist region 116, a second waist region118, and a crotch region 119 disposed intermediate the first and secondwaist regions. The first waist region 116 may be configured as a frontwaist region, and the second waist region 118 may be configured as backwaist region. The diaper 100P may also include a laterally extendingfront waist edge 121 in the front waist region 116 and a longitudinallyopposing and laterally extending back waist edge 122 in the back waistregion 118. To provide a frame of reference for the present discussion,the diaper 100P and chassis 102 of FIG. 2 are shown with a longitudinalaxis 124 and a lateral axis 126. In some embodiments, the longitudinalaxis 124 may extend through the front waist edge 121 and through theback waist edge 122. And the lateral axis 126 may extend through a firstlongitudinal or right side edge 128 and through a midpoint of a secondlongitudinal or left side edge 130 of the chassis 102.

As shown in FIGS. 1A, 1B, and 2 , the diaper pant 100P may include aninner, body facing surface 132, and an outer, garment facing surface134. The chassis 102 may include a backsheet 136 and a topsheet 138. Thechassis 102 may also include an absorbent assembly 140, including anabsorbent core 142, disposed between a portion of the topsheet 138 andthe backsheet 136. As discussed in more detail below, the diaper 100Pmay also include other features, such as leg elastics and/or leg cuffsto enhance the fit around the legs of the wearer.

As shown in FIG. 2 , the periphery of the chassis 102 may be defined bythe first longitudinal side edge 128, a second longitudinal side edge130, a first laterally extending end edge 144 disposed in the firstwaist region 116, and a second laterally extending end edge 146 disposedin the second waist region 118. Both side edges 128 and 130 extendlongitudinally between the first end edge 144 and the second end edge146. As shown in FIG. 2 , the laterally extending end edges 144 and 146are located longitudinally inward from the laterally extending frontwaist edge 121 in the front waist region 116 and the laterally extendingback waist edge 122 in the back waist region 118. When the diaper pant100P is worn on the lower torso of a wearer, the front waist edge 121and the back waist edge 122 may encircle a portion of the waist of thewearer. At the same time, the side edges 128 and 130 may encircle atleast a portion of the legs of the wearer. And the crotch region 119 maybe generally positioned between the legs of the wearer with theabsorbent core 142 extending from the front waist region 116 through thecrotch region 119 to the back waist region 118.

As previously mentioned, the diaper pant 100P may include a backsheet136. The backsheet 136 may also define the outer surface 134 of thechassis 102. The backsheet 136 may also comprise a woven or nonwovenmaterial, polymeric films such as thermoplastic films of polyethylene orpolypropylene, and/or a multi-layer or composite materials comprising afilm and a nonwoven material. The backsheet may also comprise anelastomeric film. An example backsheet 136 may be a polyethylene filmhaving a thickness of from about 0.012 mm (0.5 mils) to about 0.051 mm(2.0 mils). Further, the backsheet 136 may permit vapors to escape fromthe absorbent core (i.e., the backsheet is breathable) while stillpreventing exudates from passing through the backsheet 136.

Also described above, the diaper pant 100P may include a topsheet 138.The topsheet 138 may also define all or part of the inner surface 132 ofthe chassis 102. The topsheet 138 may be liquid pervious, permittingliquids (e.g., menses, urine, and/or runny feces) to penetrate throughits thickness. A topsheet 138 may be manufactured from a wide range ofmaterials such as woven and nonwoven materials; apertured or hydroformedthermoplastic films; apertured nonwovens, porous foams; reticulatedfoams; reticulated thermoplastic films; and thermoplastic scrims. Wovenand nonwoven materials may comprise natural fibers such as wood orcotton fibers; synthetic fibers such as polyester, polypropylene, orpolyethylene fibers; or combinations thereof. If the topsheet 138includes fibers, the fibers may be spunbond, carded, wet-laid,meltblown, hydroentangled, or otherwise processed as is known in theart. Topsheets 138 may be selected from high loft nonwoven topsheets,apertured film topsheets and apertured nonwoven topsheets. Exemplaryapertured films may include those described in U.S. Pat. Nos. 5,628,097;5,916,661; 6,545,197; and 6,107,539.

As mentioned above, the diaper pant 100P may also include an absorbentassembly 140 that is joined to the chassis 102. As shown in FIG. 2 , theabsorbent assembly 140 may have a laterally extending front edge 148 inthe front waist region 116 and may have a longitudinally opposing andlaterally extending back edge 150 in the back waist region 118. Theabsorbent assembly may have a longitudinally extending right side edge152 and may have a laterally opposing and longitudinally extending leftside edge 154, both absorbent assembly side edges 152 and 154 may extendlongitudinally between the front edge 148 and the back edge 150. Theabsorbent assembly 140 may additionally include one or more absorbentcores 142 or absorbent core layers. The absorbent core 142 may be atleast partially disposed between the topsheet 138 and the backsheet 136and may be formed in various sizes and shapes that are compatible withthe diaper. Exemplary absorbent structures for use as the absorbent coreof the present disclosure are described in U.S. Pat. Nos. 4,610,678;4,673,402; 4,888,231; and 4,834,735.

Some absorbent core embodiments may comprise fluid storage cores thatcontain reduced amounts of cellulosic airfelt material. For instance,such cores may comprise less than about 40%, 30%, 20%, 10%, 5%, or even1% of cellulosic airfelt material. Such a core may comprise primarilyabsorbent gelling material in amounts of at least about 60%, 70%, 80%,85%, 90%, 95%, or even about 100%, where the remainder of the corecomprises a microfiber glue (if applicable). Such cores, microfiberglues, and absorbent gelling materials are described in U.S. Pat. Nos.5,599,335; 5,562,646; 5,669,894; and 6,790,798 as well as U.S. PatentPublication Nos. 2004/0158212 A1 and 2004/0097895 A1.

As previously mentioned, the diaper 100P may also include elasticizedleg cuffs 156. It is to be appreciated that the leg cuffs 156 can be andare sometimes also referred to as leg bands, side flaps, barrier cuffs,elastic cuffs or gasketing cuffs. The elasticized leg cuffs 156 may beconfigured in various ways to help reduce the leakage of body exudatesin the leg regions. Example leg cuffs 156 may include those described inU.S. Pat. Nos. 3,860,003; 4,909,803; 4,695,278; 4,795,454; 4,704,115;4,909,803; and U.S. Patent Publication No. 2009/0312730 A1.

As mentioned above, diaper pants may be manufactured with a ring-likeelastic belt 104 and provided to consumers in a configuration whereinthe front waist region 116 and the back waist region 118 are connectedto each other as packaged, prior to being applied to the wearer. Assuch, diaper pants may have a continuous perimeter waist opening 110 andcontinuous perimeter leg openings 112 such as shown in FIGS. 1A and 1B.The ring-like elastic belt may be formed by joining a first elastic beltto a second elastic belt with a permanent side seam or with an openableand reclosable fastening system disposed at or adjacent the laterallyopposing sides of the belts.

As previously mentioned, the ring-like elastic belt 104 may be definedby a first elastic belt 106 connected with a second elastic belt 108. Asshown in FIG. 2 , the first elastic belt 106 extends between a firstlongitudinal side edge 111 a and a second longitudinal side edge 111 band defines first and second opposing end regions 106 a, 106 b and acentral region 106 c. And the second elastic 108 belt extends between afirst longitudinal side edge 113 a and a second longitudinal side edge113 b and defines first and second opposing end regions 108 a, 108 b anda central region 108 c. The distance between the first longitudinal sideedge 111 a and the second longitudinal side edge 111 b defines the pitchlength, PL, of the first elastic belt 106, and the distance between thefirst longitudinal side edge 113 a and the second longitudinal side edge113 b defines the pitch length, PL, of the second elastic belt 108. Thecentral region 106 c of the first elastic belt is connected with thefirst waist region 116 of the chassis 102, and the central region 108 cof the second elastic belt 108 is connected with the second waist region118 of the chassis 102. As shown in FIGS. 1A and 1B, the first endregion 106 a of the first elastic belt 106 is connected with the firstend region 108 a of the second elastic belt 108 at first side seam 178,and the second end region 106 b of the first elastic belt 106 isconnected with the second end region 108 b of the second elastic belt108 at second side seam 180 to define the ring-like elastic belt 104 aswell as the waist opening 110 and leg openings 112.

As shown in FIGS. 2, 3A, and 3B, the first elastic belt 106 also definesan outer laterally extending edge 107 a and an inner laterally extendingedge 107 b, and the second elastic belt 108 defines an outer laterallyextending edge 109 a and an inner laterally extending edge 109 b. Assuch, a perimeter edge 112 a of one leg opening may be defined byportions of the inner laterally extending edge 107 b of the firstelastic belt 106, the inner laterally extending edge 109 b of the secondelastic belt 108, and the first longitudinal or right side edge 128 ofthe chassis 102. And a perimeter edge 112 b of the other leg opening maybe defined by portions of the inner laterally extending edge 107 b, theinner laterally extending edge 109 b, and the second longitudinal orleft side edge 130 of the chassis 102. The outer laterally extendingedges 107 a, 109 a may also define the front waist edge 121 and thelaterally extending back waist edge 122 of the diaper pant 100P. Thefirst elastic belt and the second elastic belt may also each include anouter, garment facing layer 162 and an inner, wearer facing layer 164.It is to be appreciated that the first elastic belt 106 and the secondelastic belt 108 may comprise the same materials and/or may have thesame structure. In some embodiments, the first elastic belt 106 and thesecond elastic belt may comprise different materials and/or may havedifferent structures. It should also be appreciated that the firstelastic belt 106 and the second elastic belt 108 may be constructed fromvarious materials. For example, the first and second belts may bemanufactured from materials such as plastic films; apertured plasticfilms; woven or nonwoven webs of natural materials (e.g., wood or cottonfibers), synthetic fibers (e.g., polyolefins, polyamides, polyester,polyethylene, or polypropylene fibers) or a combination of naturaland/or synthetic fibers; or coated woven or nonwoven webs. In someembodiments, the first and second elastic belts include a nonwoven webof synthetic fibers, and may include a stretchable nonwoven. In otherembodiments, the first and second elastic belts include an innerhydrophobic, non-stretchable nonwoven material and an outer hydrophobic,non-stretchable nonwoven material.

The first and second elastic belts 106, 108 may also each include beltelastic material interposed between the outer substrate layer 162 andthe inner substrate layer 164. The belt elastic material may include oneor more elastic elements such as strands, ribbons, films, or panelsextending along the lengths of the elastic belts. As shown in FIGS. 2,3A, and 3B, the belt elastic material may include a plurality of elasticstrands 168 which may be referred to herein as outer, waist elastics 170and inner, waist elastics 172. Elastic strands 168, such as the outerwaist elastics 170, may continuously extend laterally between the firstand second opposing end regions 106 a, 106 b of the first elastic belt106 and between the first and second opposing end regions 108 a, 108 bof the second elastic belt 108. In some embodiments, some elasticstrands 168, such as the inner waist elastics 172, may be configuredwith discontinuities in areas, such as for example, where the first andsecond elastic belts 106, 108 overlap the absorbent assembly 140. Insome embodiments, the elastic strands 168 may be disposed at a constantinterval in the longitudinal direction. In other embodiments, theelastic strands 168 may be disposed at different intervals in thelongitudinal direction. The belt elastic material in a stretchedcondition may be interposed and joined between the uncontracted outerlayer and the uncontracted inner layer. When the belt elastic materialis relaxed, the belt elastic material returns to an unstretchedcondition and contracts the outer layer and the inner layer. The beltelastic material may provide a desired variation of contraction force inthe area of the ring-like elastic belt. It is to be appreciated that thechassis 102 and elastic belts 106, 108 may be configured in differentways other than as depicted in FIG. 2 . The belt elastic material may bejoined to the outer and/or inner layers continuously or intermittentlyalong the interface between the belt elastic material and the innerand/or outer belt layers.

In some configurations, the first elastic belt 106 and/or second elasticbelt 108 may define curved contours. For example, the inner lateraledges 107 b, 109 b of the first and/or second elastic belts 106, 108 mayinclude non-linear or curved portions in the first and second opposingend regions. Such curved contours may help define desired shapes to legopening 112, such as for example, relatively rounded leg openings. Inaddition to having curved contours, the elastic belts 106, 108 mayinclude elastic strands 168, 172 that extend along non-linear or curvedpaths that may correspond with the curved contours of the inner lateraledges 107 b, 109 b.

It is to be appreciated that the apparatuses and methods of assembly ofelastomeric laminates and absorbent articles described herein andillustrated in the accompanying drawings are non-limiting exampleconfigurations. The features illustrated or described in connection withone non-limiting configuration may be combined with the features ofother non-limiting configurations. Such modifications and variations areintended to be included within the scope of the present disclosure.

Some configurations of the methods and apparatuses according to thepresent disclosure may utilize a plurality of elastic strands wound ontoa beam, wherein one or more elastic strands comprises a spin finish.During assembly of an elastomeric laminate, the beam is rotated tounwind the elastic strands from the beam. The elastic strands may bestretched while advancing in a machine direction. A portion of the spinfinish may be removed from the advancing elastic strand with a spinfinish removal apparatus. As discussed below, the spin finish removalapparatus may treat the advancing elastic strand to remove some or allthe spin finish from the elastic strand. The spin finish removalapparatus may be configured to apply detergent to an advancing elasticstrand and may also wipe and/or dry the advancing elastic strand. Thetreated stretched elastic strand may then be connected between a firstsubstrate and a second substrate. In some configurations, adhesive maybe applied to the treated the elastic strand, the first substrate,and/or the second substrate. As such, the methods and apparatuses areadapted to utilize elastic strands having a spin finish that are unwoundfrom beams to produce elastomeric laminates. By removing the spin finishfrom the elastics strands, relatively less adhesive may be utilized toadhere the strands between the substrates.

As previously mentioned, apparatuses and methods according to thepresent disclosure may be utilized to produce elastomeric laminates thatmay be used to construct various components of diapers, such as elasticbelts, leg cuffs, and the like. For example, FIGS. 4-11 show schematicviews of converting apparatuses 300 adapted to manufacture elastomericlaminates 302. As described in more detail below, the convertingapparatuses 300 shown in FIGS. 4-11 operate to advance a continuouslength of elastic material 304, a continuous length of a first substrate306, and a continuous length of a second substrate 308 along a machinedirection MD. It is also to be appreciated that in some configurations,the first substrate 306 and second substrate 308 herein may be definedby two discrete substrates or may be defined by folded portions of asingle substrate. The apparatus 300 stretches the elastic material 304and joins the stretched elastic material 304 with the first and secondsubstrates 306, 308 to produce an elastomeric laminate 302. Although theelastic material 304 is illustrated and referred to herein as strands,it is to be appreciated that elastic material 304 may include one ormore continuous lengths of elastic strands, ribbons, and/or films.

It is to be appreciated that the elastomeric laminates 302 can be usedto construct various types of absorbent article components. It also tobe appreciated that the methods and apparatuses herein may be adapted tooperate with various types of absorbent article assembly processes, suchas disclosed for example in U.S. Patent Publication Nos. 2013/0255861A1; 2013/0255862 A1; 2013/0255863 A1; 2013/0255864 A1; and 2013/0255865A1. For example, the elastomeric laminates 302 may be used as acontinuous length of elastomeric belt material that may be convertedinto the first and second elastic belts 106, 108 discussed above withreference to FIGS. 1-3B. As such, the elastic material 304 maycorrespond with the belt elastic material 168 interposed between theouter layer 162 and the inner layer 164, which in turn, may correspondwith either the first and/or second substrates 306, 308. In otherexamples, the elastomeric laminates may be used to construct waistbandsand/or side panels in taped diaper configurations. In yet otherexamples, the elastomeric laminates may be used to construct varioustypes of leg cuff and/or topsheet configurations.

As discussed in more detail below, the converting apparatuses 300 mayinclude metering devices arranged along a process machine direction MD,wherein the metering devices may be configured to stretch the advancingelastic material and/or join stretch elastic material with one or moreadvancing substrates. In some configurations, a metering device maycomprise a beam of elastic strands wound thereon. During operation,elastic material may advance in a machine direction from a rotating beamto a downstream metering device to be joined with one or more advancingsubstrates. The elastic material advancing from the rotating beam mayinclude a spin finish, and as such, the apparatuses herein may beconfigured to remove some or all the spin finish before joining theelastic material with the substrates.

As shown in FIGS. 4-6 , a converting apparatus 300 for producing anelastomeric laminate 302 may include a first metering device 310 and asecond metering device 312. The first metering device may be configuredas a beam 314 with a plurality of elastic strands 316 wound thereon.FIG. 4 shows an example of an empty beam 314 that includes two sideplates 317 a, 317 b that may be connected with opposing end portions ofa mandrel core 318, wherein elastic strands may be wound onto themandrel core 318. It is to be appreciated that beams of various sizesand technical specifications may be utilized in accordance with themethods and apparatuses herein, such as for example, beams that areavailable from ALUCOLOR Textilmaschinen, GmbH. It is to be appreciatedthat various methods and apparatuses may be used to assemble elasticstrands and/or beams and to wind elastic strands on beams. For example,in some configurations, the tension of elastic strands may be controlledto desired levels when winding elastic strands onto a beam. During thebeam winding process, reeds used to separate elastic strands may beoscillated back and forth and/or the beam may be oscillated back andforth to help ensure uniform winding of the elastic strands on thebeams.

During operation, the plurality of elastic strands 316 advance in themachine direction MD from the beam 314 to the second metering device312. In addition, the plurality of elastic strands 316 may be stretchedalong the machine direction MD between the beam 314 and the secondmetering device 312. The stretched elastic strands 316 are also joinedwith a first substrate 306 and a second substrate 308 at the secondmetering device 312 to produce an elastomeric laminate 302. As discussedin more detail below, one or more of the elastic strands 316′ advancingfrom the beam 314 may include a spin finish 320 located on outersurfaces of the elastics strands. In turn, all or some of the spinfinish 320 may be removed from the advancing elastic strands 316′ with aspin finish removal apparatus 322. In turn, treated stretched elasticstrands 316″ may then be connected between the first substrate 306 andthe second substrate 308.

It is to be appreciated the elastic strands 316 may include varioustypes of spin finish 320, also referred herein as yarn finish,configured as coating on the elastic strands 316 that may be intended tohelp prevent the elastics strands from adhering to themselves, eachother, and/or downstream handling equipment. In some configurations, aspin finish may include various types of oils and other components, suchas disclosed for example in U.S. Pat. Nos. 8,377,554; 8,093,161; and6,821,301. In some configurations, a spin finish may include varioustypes of silicone oils, such as for example, polydimethylsiloxane. Insome configurations, a spin finish may include various types of mineraloils, including hydrogenated paraffinic and napthenic oils. In someconfigurations, the molecular weight of an oil may be adjusted tooptimize adhesion properties of the elastic strands depending on theprocess configuration in which the elastic strands may be used. In someconfigurations, a spin finish may include various types of fatty amides,erucamide, behenamide, and oleamide. It is also to be appreciated thatthe amount of spin finish applied to elastic strands may be optimizeddepending on the process configuration in which the elastic strands maybe used. For example, in process configurations wherein elastic strandshave limited contact or do not contact downstream handling equipment,such as idlers, the amount of spin finish may be selected to helpprevent the elastics strands from adhering to themselves and/or eachother while wound on a beam without regard to whether elastic strandswould adhere to downstream handling equipment. As such, it is to beappreciated that the elastic strands herein may include various amountsof spin finish that may be expressed in various ways. For example, aquantity of 10 grams of spin finish per 1 kilogram of elastic strand maybe expressed as 1% spin finish. In some configurations, an elasticstrand may include about 0.1% spin finish. In some configurations, astrand may include from about 0.01% to about 10% spin finish,specifically reciting all 0.01% increments within the above-recitedrange and all ranges formed therein or thereby.

As shown in FIGS. 5 and 6 , the second metering device 312 may include:a first roller 324 having an outer circumferential surface 326 and thatrotates about a first axis of rotation 328, and a second roller 330having an outer circumferential surface 332 and that rotates about asecond axis of rotation 334. The first roller 324 and the second roller330 rotate in opposite directions, and the first roller 324 is adjacentthe second roller 330 to define a nip 336 between the first roller 324and the second roller 330. The first roller 324 rotates such that theouter circumferential surface 326 has a surface speed S1, and the secondroller 330 may rotate such that the outer circumferential surface 332has the same, or substantially the same, surface speed S1.

With continued reference to FIGS. 5 and 6 , the first substrate 306includes a first surface 338 and an opposing second surface 340, and thefirst substrate 306 advances to the first roller 324. In particular, thefirst substrate 306 advances at speed S1 to the first roller 324 wherethe first substrate 306 partially wraps around the outer circumferentialsurface 326 of the first roller 324 and advances through the nip 336. Assuch, the first surface 338 of the first substrate 306 travels in thesame direction as and in contact with the outer circumferential surface326 of the first roller 324. In addition, the second substrate 308includes a first surface 342 and an opposing second surface 344, and thesecond substrate 308 advances to the second roller 330. In particular,the second substrate 308 advances at speed S1 to the second roller 330where the second substrate 308 partially wraps around the outercircumferential surface 332 of the second roller 330 and advancesthrough the nip 336. As such, the second surface 344 of the secondsubstrate 308 travels in the same direction as and in contact with theouter circumferential surface 332 of the second roller 330.

Still referring to FIGS. 5 and 6 , the beam 314 includes elastic strands316 wound thereon, and the beam 314 is rotatable about a beam rotationaxis 346. In some configurations, the beam rotation axis 346 may extendin the cross direction CD. As the beam 314 rotates, the elastic strands316 advance from the beam 314 at a speed S2 with the elastic strands 316being spaced apart from each other in the cross direction CD. From thebeam 314, the elastic strands 316 advance in the machine direction MD tothe nip 336. In some configurations, the speed S2 is less than the speedS1, and as such, the elastic strands 316 are stretched in the machinedirection MD. In turn, the stretched elastic strands 316 advance throughthe nip 336 between the first and second substrates 306, 308 such thatthe elastic strands 316 are joined with the second surface 340 of thefirst substrate 306 and the first surface 342 of the second substrate308 to produce a continuous length of elastomeric laminate 302.

As discussed above, one or more of the elastic strands 316′ advancingfrom the beam 314 may include a spin finish 320. In turn, the advancingelastic strands 316′ may be treated with the spin finish removalapparatus 322 that may remove some or all the spin finish 320. As such,the treated elastic strands 316″ having some or all the spin finish 320removed may advance from the spin finish removal apparatus 322 to bejoined with the first substrate 306 and the second substrate 308 to formthe elastomeric laminate 302. As shown in FIG. 5 , the first substrate306 may advance past an adhesive applicator device 348 that appliesadhesive 350 to the second surface 340 of the first substrate 306 beforeadvancing to the nip 336. It is to be appreciated that the adhesive 350may be applied to the first substrate 306 upstream of the first roller324 and/or while the first substrate 306 is partially wrapped around theouter circumferential surface 326 of the first roller 324. It is to beappreciated that adhesive may be applied to the treated elastic strands316″ before and/or while being joined with first substrate 306 andsecond substrate 308. In addition, it is to be appreciated that adhesivemay be applied to the first surface 342 of the second substrate 308before or while being joined with the treated elastic strands 316″ andthe first substrate 306. It is also to be appreciated that untreated316′ and/or treated elastic strands 316″ may be bonded with the firstsubstrate 306 and/or second substrate 308 with the various methods andapparatuses described herein and combinations thereof.

As shown in FIGS. 5 and 6 , the spin finish removal apparatus 322 may beconfigured to include a bath 352 containing a detergent 354. As such theelastic strands 316′ having a spin finish 320 advance from the beam 314to the bath 352, wherein the elastic strands 316′ advance through thedetergent 354 adapted to remove some or all the spin finish 320 from theelastic strands 316. As shown in FIGS. 5 and 6 , the spin finish removalapparatus 322 may also be configured to include a drying apparatus 356to remove the detergent 354 from the elastic strands 316. It is to beappreciated that the drying apparatus 356 may be configured in variousways, such as a fan, a blower, a heater, and/or combinations thereof. Insome configurations, the drying apparatus 356 may move air or some othergas 358 relative to the elastic strands 316 to evaporate the detergentfrom the elastic strands 316. As such, the treated elastic strands 316″may advance from the bath 352 to the drying apparatus 356 to remove someor all the detergent from the treated elastic strands 316″. In turn, thetreated elastic strands 316″ may advance from the drying apparatus 356to be combined with the first substrate 306 and the second substrate308. Although FIG. 6 shows nine elastic strands 316 advancing from thebeam 314, it is to be appreciated that the apparatuses herein may beconfigured such that more or less than nine elastic strands 316 advancefrom the beam 314.

It is to be appreciated that various configurations of detergent 354 maybe used to remove spin finish 320 from the elastic strands 316. Forexample, in some configurations, a detergent may include variousdifferent ingredients, such as those included for example in TISSOCYL RCavailable from Zschimmer & Schwarz GmbH.

It is to be appreciated that different components may be used toconstruct the elastomeric laminates 302 in accordance with the methodsand apparatuses herein. For example, the first and/or second substrates306, 308 may include nonwovens and/or films and may be constructed fromvarious types of materials, such as plastic films; apertured plasticfilms; woven or nonwoven webs of natural materials, such as wood orcotton fibers; synthetic fibers, such as polyolefins, polyamides,polyester, polyethylene, or polypropylene fibers or a combination ofnatural and/or synthetic fibers; or coated woven or nonwoven webs;polymeric films such as thermoplastic films of polyethylene orpolypropylene, and/or a multi-layer or composite materials comprising afilm and a nonwoven material. In addition, the elastic strands 316herein may be configured in various ways and having various decitexvalues. In some configurations, the elastic strands 316 may beconfigured with decitex values ranging from about 10 decitex to about500 decitex, specifically reciting all 1 decitex increments within theabove-recited range and all ranges formed therein or thereby.

It is also to be appreciated the beams 314 herein may be configured invarious ways and with various quantities of elastic strands. Examplebeams, also referred to as warp beams, that may be used with theapparatus and methods herein are disclosed in U.S. Pat. Nos. 4,525,905;5,060,881; and 5,775,380; and U.S. Patent Publication No. 2004/0219854A1. In some configurations, the elastic strands 316 advancing from thebeam 314 may include from about 100 to about 2000 strands, specificallyreciting all 1 strand increments within the above-recited range and allranges formed therein or thereby. In some configurations, the elasticstrands 316 may be separated from each other by about 0.5 mm to about 4mm in the cross direction, specifically reciting all 0.1 mm incrementswithin the above-recited range and all ranges formed therein or thereby.As discussed herein, the elastics in the plurality of elastic strandsmay be pre-strained prior to joining the elastic strand to the first orsecond substrate layers 306, 308. In some configurations, the elasticmay be pre-strained from about 75% to about 300%, specifically recitingall 1% increments within the above-recited range and all ranges formedtherein or thereby. Pre-strain refers to the strain imposed on anelastic or elastomeric material prior to combining it with anotherelement of the elastomeric laminate or the absorbent article. Pre-strainis determined by the following equation: Pre-strain=((extended length ofthe elastic-relaxed length of the elastic)/relaxed length of theelastic)*100. It is also to be appreciated that one or more beams ofelastics may be arranged along the cross direction CD of a convertingprocess and/or arranged along a machine direction MD in variousdifferent portions of a converting process. It is also to be appreciatedthat the beam 314 can be connected with one or more motors, such asservo motors, to drive and control the rotation of the beam 314. It isto be appreciated that in some configurations, the elastic strands 316may be supplied on the beam 314 in a stretched state, and as such, maynot require additional stretching (or may require relatively lessadditional stretching) before being combined with the first substrate306 and/or the second substrate 308. In some configurations, an elasticstrand 316 may be drawn from a single roll utilizing a rolling unwind,such as for example, available from Overend Technologies, Inc.

It is to be appreciated that the apparatuses 300 herein may beconfigured in various ways with various features described herein toassemble elastomeric laminates 302 having various stretchcharacteristics. For example, the apparatus 300 may be configured toassemble elastomeric laminates 302 with elastic strands 316 unwound frommore than one beam and/or in combination with elastic stands suppliedfrom an overend unwinder.

The elastic strands 316 may be joined with the first and secondsubstrates 306, 308 such that the elastomeric laminate 302 may havedifferent stretch characteristics in different regions along the crossdirection CD. For example, when the elastomeric laminate 302 iselongated, some elastic strands may exert contraction forces in themachine direction MD that are different from contraction forces exertedby other elastic strands. Such differential stretch characteristics canbe achieved by stretching some elastic strands more or less than otherelastic strands before joining the elastic strands with the first andsecond substrates 306, 308. It is also to be appreciated that theelastic strands may have various different material constructions and/ordecitex values to create elastomeric laminates 302 having differentstretch characteristics in different regions. In some configurations,the elastomeric laminate may have regions where the elastic strands arespaced relatively close to one another in the cross direction CD andother regions where the elastic strands are spaced relatively fartherapart from each other in the cross direction CD to create differentstretch characteristics in different regions. In some configurations,the elastic strands 316 may be supplied on the beam in a stretchedstate, and as such, may not require additional stretching (or mayrequire relatively less additional stretching) before being combinedwith the first substrate 306 and/or the second substrate 308.

It is to be appreciated that the spin finish removal apparatus 322 maybe configured in various ways. For example as shown in FIG. 7 , the spinfinish removal apparatus 322 may include one or more detergentapplicator devices 360, such as a nozzle, that sprays detergent 354 ontothe spin finish 320 of advancing elastic strands 316′. With continuedreference to FIG. 7 , the spin finish removal apparatus 322 may alsoinclude a wiper 362 downstream of the detergent applicator device 360that is configured to wipe detergent 354 and/or spin finish 320 from theelastic strands 316. The elastic strands 316 may then advance from thewiper 362 to the drying apparatus 356 such as described above. It is tobe appreciated that the wiper 362 may be in direct contact with theelastic strands and may be configured as a static device or may beconfigured to move relative to the elastic strands 316. For example, thewiper 362 may be configured with an outer surface in contact with theelastic strands 316 that rotates in a direction opposite of the machinedirection MD of the advancing elastic strands 316. In someconfigurations, the wiper 362 may be configured with an outer surface incontact with the elastic strands 316 that rotates in a same direction asthe machine direction MD of the advancing elastic strands 316 whereinthe outer surface may move faster or slower than the speed of theelastic strands 316.

In some configurations, the first and/or second substrates 306, 308 maybe used in conjunction with a wiper 362 to remove detergent 354 and/orspin finish 320 from the elastic strands 316. For example, FIG. 8 showsa configuration wherein the advancement path of second substrate 308 isconfigured such that the second substrate 308 contacts the elasticstrands 316 to remove detergent 354 and/or spin finish 320. As shown inFIG. 8 , the spin finish removal apparatus 322 may include one or morerotating drums 364 arranged such that before the second substrate 308 iscombined with the elastic strands 316 and the first substrate 306, thesecond substrate 308 contacts the elastic strands 316. For example, thesecond substrate 308 may advance onto a first drum 364 a wherein thesecond substrate 308 advances at a first speed S1. The first drum 364 arotates and brings first surface 342 of the second substrate 308 intocontact with the elastic strands 316 advancing at a second speed S2,wherein S1 is not equal S2. As such, the second substrate 308 and theelastic strands 316 move relative to each other when in contact. Inturn, the relative movement between the second substrate 308 and theelastic strands 316 may wipe detergent 354 and/or spin finish 320 fromthe elastic strands 316. From the first drum 364 a, the second substrate308 may advance to a second drum 364 b before being combined with theelastic strands 316 and the first substrate 306 to form the elastomericlaminate 302.

It is to be appreciated that the advancement path of either or both thefirst substrate 306 and the second substrate 308 may be configured suchthat either or both the first substrate 306 and the second substrate 308may advance and contact to the elastic strands 316 to wipe detergent 354and/or spin finish 320 from the elastic strands 316. It is also to beappreciated that that the first surface 338 and/or the second surface340 of the first substrate 306 and/or the first surface 342 and/or thesecond surface 344 of the second substrate 308 may be used to contactthe elastic strands 316 and wipe detergent 354 and/or spin finish 320from the elastic strands 316. In some configurations, the advancementpath of the assembled elastic laminate 302 may be configured such thatthe either or both the first substrate 306 and the second substrate 308of the elastic laminate 302 may contact the elastic strands 316 and wipedetergent 354 and/or spin finish 320 from the elastic strands 316 beforethe elastic strands 316 are joined with the first substrate 306 and thesecond substrate 308. In some configurations, the spin finish 320 and/ordetergent 354 may be wiped onto one surface of either or both the firstand second substrates 306, 308 and wherein the elastic strands 316 arebonded to the opposing surface of either or both the first and secondsubstrates 306, 308 to help improve adhesion of the elastic strands 316to the first substrate 306 and/or the second substrate 308.

It is to be appreciated that the apparatuses 300 herein may beconfigured in various ways with various features of the spin finishremoval apparatuses 322 described herein to assemble elastomericlaminates 302. For example, in another configuration of the apparatus300 shown in FIG. 9 , the second roller 330 may be positioned downstreamfrom the first roller 324. As such, the first roller 324 may beconfigured as the second metering device 312 and the second roller 330may be configured as a third metering device 366. As shown in FIG. 9 ,the first substrate 306 advances at speed S1 to the first roller 324where the first substrate 306 partially wraps around the outercircumferential surface 326 of the first roller 324 and advances fromthe first roller to the second roller 330 to be combined with secondsubstrate 308. As the beam 314 rotates, the elastic strands 316 advancefrom the beam 314 at a speed S2 with the elastic strands 316 beingspaced apart from each other in the cross direction CD. From the beam314, elastic strands 316′ having a spin finish 320 advance to a spinfinish removal apparatus 322 generically illustrated by a dashed-linerectangle. It is to be appreciated that the spin finish removalapparatus 322 may be configured with various combinations of features ofthe spin finish removal apparatus 322 described herein. In turn, all orsome of the spin finish 320 may be removed from the advancing elasticstrands 316′ with the spin finish removal apparatus 322. As such, thetreated elastic strands 316″ having some or all the spin finish 320removed may advance from the spin finish removal apparatus 322 to thefirst roller 324 and are positioned on the second surface 340 of thefirst substrate 306. In some configurations, the speed S2 is less thanthe speed S1, and as such, the elastic strands 316 are stretched in themachine direction MD.

With continued reference to FIG. 9 , the first substrate 306 and theelastic strands 316 advance from the outer circumferential surface 326of the first roller 324 to the second roller 330. In addition, thesecond substrate 308 advances at speed S1 to the second roller 330 wherethe second substrate 308 partially wraps around the outercircumferential surface 332 of the second roller 330. In turn, thecombined first substrate 306 and the stretched elastic strands 316, 316″advance from first roller 324 to the second roller 330 and are combinedwith the second substrate 308 such that the elastic strands 316, 316″are joined with the second surface 340 of the first substrate 306 andthe first surface 342 of the second substrate 308 to produce acontinuous length of elastomeric laminate 302. As discussed above, thefirst substrate 306 may advance past an adhesive applicator device 348that applies adhesive 350 to the second surface 340 of the firstsubstrate 306 while advancing to the first roller 324. It is to beappreciated that the adhesive 350 may be applied to the first substrate306 while the first substrate 306 is partially wrapped around the outercircumferential surface 326 of the first roller 324. It is to beappreciated that adhesive may also be applied to the elastic strands316, 316″ before and/or while being joined with first substrate 306 andsecond substrate 308. In addition, it is to be appreciated that adhesivemay be applied to the first surface 342 of the second substrate 308before or while being joined with the elastic strands 316 and firstsubstrate 306.

In another configuration shown in FIG. 10 , the apparatus 300 may beconfigured with only the first roller 324 and without a second roller330. As such, the first roller 324 may be configured as the secondmetering device 312. As shown in FIG. 10 , the first substrate 306advances at speed S1 to the first roller 324 where the first substrate306 partially wraps around the outer circumferential surface 326 of thefirst roller 324. While partially wrapped around the outercircumferential surface 326 of the first roller 324, the first substrate306 is combined with the elastic strands 316, 316″ and the secondsubstrate 308. As the beam 314 rotates, the elastic strands 316 advancefrom the beam 314 at a speed S2 with the elastic strands 316 beingspaced apart from each other in the cross direction CD. From the beam314, elastic strands 316′ having a spin finish 320 advance to a spinfinish removal apparatus 322 generically illustrated by a dashed-linerectangle. As discussed above, it is to be appreciated that the spinfinish removal apparatus 322 may be configured with various combinationsof features of the spin finish removal apparatus 322 described herein.In turn, all or some of the spin finish 320 may be removed from theadvancing elastic strands 316′ with the spin finish removal apparatus322. As such, the treated elastic strands 316″ having some or all thespin finish 320 removed may advance from the spin finish removalapparatus 322 to the first roller 324 and are positioned on the secondsurface 340 of the first substrate 306. In some configurations, thespeed S2 is less than the speed S1, and as such, the elastic strands 316are stretched in the machine direction MD.

With continued reference to FIG. 10 , the second substrate 308 advancesat speed S1 to the first roller 324 and partially wraps around the outercircumferential surface 326 of the first roller 324. In turn, the secondsubstrate 308 is combined with the first substrate 306 and the stretchedelastic strands 316 while on the first roller 324 such that the elasticstrands 316 are joined with the second surface 340 of the firstsubstrate 306 and the first surface 342 of the second substrate 308 toproduce a continuous length of elastomeric laminate 302. As discussedabove, the first substrate 306 may advance past an adhesive applicatordevice 348 that applies adhesive 350 to the second surface 340 of thefirst substrate 306 while advancing to the first roller 324. It is to beappreciated that the adhesive 350 may be applied to the first substrate306 while the first substrate 306 is partially wrapped around the outercircumferential surface 326 of the first roller 324. It is to beappreciated that adhesive may also be applied to the elastic strands 316before and/or while being joined with first substrate 306 and secondsubstrate 308. In addition, it is to be appreciated that adhesive may beapplied to the first surface 342 of the second substrate 308 before orwhile being joined with the elastic strands 316 and first substrate 306.

As illustrated herein, the apparatuses and processes may be configuredsuch that elastic strands may be advanced from the beams and directly tothe assembly process without having to touch additional machinecomponents, such as for example, guide rollers. It is also to beappreciated that in some configurations, elastic strands may be advancedfrom beams and may be redirected and/or otherwise touched by and/orredirected before advancing to the assembly process. For example, FIG.11 shows a configuration where the beam rotation axis 346 may extend ina first cross direction CD1. As the beam 314 rotates, the elasticstrands 316 advance from the beam 314 in a first machine direction MD1with the elastic strands 316 being spaced apart from each other in thefirst cross direction CD1. The elastic strands 316 may then beredirected by rollers 321 from the first machine direction MD1 to asecond machine direction MD2, wherein the elastic strands 316 may remainseparated from each other in a second cross direction CD2. From therollers 321, the elastic strands 316 may advance in the second machinedirection MD2 to be combined with the first and second substrates 306,308 to form the elastomeric laminate 302. Thus, it is to be appreciatedthat the beam 314 may be arranged and/or oriented such that the beamrotation axis 346 may be parallel, perpendicular, or otherwise angularlyoffset with respect to the machine direction advancement of theelastomeric laminate 302 and/or the substrates 306, 308. It is also tobe appreciated that the elastic laminate 302 may be assembled andadvanced in a machine direction that is parallel with a machinedirection of another assembly process, such as an absorbent articleassembly process that incorporates the advancing elastic laminate 302.In some configurations, the elastic laminate 302 may be assembled andadvanced in a machine direction that is perpendicular or otherwiseangularly offset with respect to a machine direction of another assemblyprocess, such as an absorbent article assembly process that incorporatesthe advancing elastic laminate 302. As such, the elastic laminate 302may advance over a turn bar, web twist, or other similar device tochange the machine direction of the advancing elastic laminate 302 asneeded for incorporation into another assembly process.

The apparatus shown in FIG. 11 also includes a spin finish removalapparatus 322 generically illustrated by a dashed-line rectangle, whichmay be configured with various combinations of features of the spinfinish removal apparatus 322 described herein. As discussed above, thespin finish removal apparatus 322 is configured to remove all or some ofthe spin finish 320 from the advancing elastic strands 316′. And inturn, the treated elastic strands 316″ having some or all the spinfinish 320 removed may advance downstream to be joined with the firstsubstrate 306 and the second substrate 308. It is to be appreciated thatthe spin finish removal apparatus 322 may be positioned in variouslocations along the advancement path of the elastic strands 316. Forexample, the spin finish removal apparatus 322 may be positionedupstream or downstream of the rollers 321 shown in FIG. 11 .

As discussed above, the methods and apparatuses according to the presentdisclosure may be configured with a plurality of elastic strands woundonto a beam, wherein one or more elastic strands comprises a spinfinish. During assembly of an elastomeric laminate, the beam is rotatedto unwind the elastic strands from the beam. The elastic strands may bestretched while advancing in a machine direction. In some configurationsdiscussed below, first bonds may be applied to bond discrete lengths ofthe spin finish on the stretched elastic strands with and between thefirst substrate and the second substrate, wherein the discrete firstbonds are arranged intermittently along the machine direction. Inaddition, second bonds may be applied between consecutive first bonds tobond the first and second substrates directly to each other, wherein thesecond bonds extend in the machine direction and are separated from eachother in a cross direction by at least one elastic strand. As discussedin more detail below, adhesive may be used to create the first bonds andsecond bonds. And in some configurations, the first bonds and/or thesecond bonds may be in the form of mechanical bonds, such as forexample, heat, pressure, and/or ultrasonic bonds. Thus, the methods andapparatuses are adapted to utilize elastic strands having a spin finishthat are unwound from beams to produce elastomeric laminates. Byutilizing the disclosed arrangements of first and second bonds,relatively less adhesive may be utilized to adhere the strands betweenthe substrates without having to remove the spin finish from the elasticstrands.

As previously mentioned, apparatuses and methods according to thepresent disclosure may be utilized to produce elastomeric laminates thatmay be used to construct various components of diapers, such as elasticbelts, leg cuffs, and the like. For example, FIGS. 12-25 show variousaspects of converting apparatuses 300 adapted to manufacture elastomericlaminates 302. As described in more detail below, the convertingapparatuses 300 operate to advance a continuous length of elasticmaterial 304, a continuous length of a first substrate 306, and acontinuous length of a second substrate 308 along a machine directionMD. The apparatus 300 stretches the elastic material 304 and joins thestretched elastic material 304 with the first and second substrates 306,308 to produce an elastomeric laminate 302. Although the elasticmaterial 304 is illustrated and referred to herein as strands, it is tobe appreciated that elastic material 304 may include one or morecontinuous lengths of elastic strands, ribbons, and/or films. It is alsoto be appreciated that in some configurations, the first substrate andsecond substrate 306, 308 herein may be defined by two discretesubstrates or may be defined by folded portions of a single substrate.

As discussed in more detail below, the converting apparatuses 300 mayinclude metering devices arranged along a process machine direction MD,wherein the metering devices may be configured to stretch the advancingelastic material and/or join stretch elastic material with one or moreadvancing substrates. In some configurations, a metering device maycomprise a beam of elastic strands wound thereon. During operation,elastic material may advance in a machine direction from a rotating beamto a downstream metering device to be joined with one or more advancingsubstrates. The elastic material advancing from the rotating beam mayinclude a spin finish, and as such, the apparatuses herein may beconfigured to bond the elastic material with the substrates withouthaving to remove the spin finish before joining the elastic materialwith the substrates. First bonds are applied to bond discrete lengths ofthe spin finish on the stretched elastic strands with and between thefirst substrate and the second substrate, and second bonds are appliedbetween consecutive first bonds to bond the first and second substratesdirectly to each other. The discrete first bonds are arrangedintermittently along the machine direction, the second bonds extend inthe machine direction and are separated from each other in a crossdirection by at least one elastic strand. It is to be appreciated thatthe apparatuses and methods of assembly of elastomeric laminates andabsorbent articles described herein and illustrated in the accompanyingdrawings are non-limiting example configurations. The featuresillustrated or described in connection with one non-limitingconfiguration may be combined with the features of other non-limitingconfigurations. Such modifications and variations are intended to beincluded within the scope of the present disclosure.

As shown in FIGS. 12-24 , a converting apparatus 300 for producing anelastomeric laminate 302 may include a first metering device 310 and asecond metering device 312. The first metering device may be configuredas a beam 314 with a plurality of elastic strands 316 wound thereon.During operation, the plurality of elastic strands 316 advance in themachine direction MD from the beam 314 to the second metering device312. In addition, the plurality of elastic strands 316 may be stretchedalong the machine direction MD between the beam 314 and the secondmetering device 312. The stretched elastic strands 316 are also joinedwith a first substrate 306 and a second substrate 308 at the secondmetering device 312 to produce an elastomeric laminate 302. As discussedin more detail below, one or more of the elastic strands 316 advancingfrom the beam 314 may include a spin finish 320 located on outersurfaces of the elastics strands. In turn, stretched elastic strands 316may be connected between the first substrate 306 and the secondsubstrate 308 with first bonds 368 and second bonds 370. The first bonds368 may be configured to anchor and bond discrete lengths of thestretched elastic strands 316 with spin finish 320 thereon with andbetween the first substrate 306 and the second substrate 308, and secondbonds 370 may be configured to bond the first and second substrates 306,308 directly to each other, wherein the second bonds 370 are separatedfrom each other in a cross direction by at least one elastic strand 316,and as such, the elastic strands 316 may be trapped between the secondbonds 370.

FIGS. 12 and 13 show an arrangement of first and second rollers 324, 330and associated features described above with reference to FIGS. 5 and 6that may be utilized to combine elastic strands 316 and first and secondsubstrates 306, 308 to produce a continuous length of elastomericlaminate 302. Although FIG. 13 shows five elastic strands 316 advancingfrom the beam 314, it is to be appreciated that the apparatuses hereinmay be configured such that more or less than five elastic strands 316advance from the beam 314.

As discussed above, one or more of the elastic strands 316 advancingfrom the beam 314 may include a spin finish 320. In turn, the advancingelastic strands 316 may be joined with the first substrate 306 and thesecond substrate 308 to form the elastomeric laminate 302 with firstbonds 368 and second bonds 370. The first bonds 368 and second bonds 370may be configured to secure the elastic strands 316 between the firstand second substrates 306, 308 without having to remove the spin finish320 from the elastic strands 316. It is also to be appreciated that themethods and apparatuses herein may also be configured to remove the spinfinish 320 from the elastic strands 316. Examples of spin finish removalprocesses and apparatuses are discussed above and are disclosed in U.S.Provisional Patent Application No. 62/483,965, which is incorporated byreference herein. As shown in FIGS. 12 and 14 , the first substrate 306may advance past a first bond applicator 372 configured to apply thefirst bonds 368 to the first substrate 306. And as shown in FIGS. 12 and15 , the first substrate 306 may advance from the first bond applicator372 to a second bond applicator 374 configured to apply the second bonds370 to the first substrate 306. In turn, the first substrate 306 mayadvance from the second bond applicator 374 to be combined with theelastic strands 316 and the second substrate 308.

As shown in FIGS. 12-14 , the first bonds 368 extend for discretelengths along the machine direction MD and may be intermittentlyarranged along the machine direction of the first substrate 306. Whenthe first substrate 306 is combined with the second substrate 308 andthe elastic strands 316 to form the elastomeric laminate 302, the firstbonds 368 are positioned to bond discrete lengths of the spin finish 320on the stretched elastic strands 316 with and between the firstsubstrate 306 and the second substrate 308, such as shown in FIG. 13 .It is to be appreciated the first bonds 368 may extend contiguously forvarious lengths in the cross direction CD and may extend across one ormore elastic strands 316. In some configurations, the first bonds 368may be defined by one or more regions of first adhesive 378 arranged toextend in the cross direction CD. Because the first bonds 368 act toadhere the spin finish 320 of the elastic strands 316 with the first andsecond substrates 306, 308, the first bonds 368 may be formed withrelatively large basis weights of the first adhesive 378. For example,in some configurations, the first bonds 368 may include first adhesive378 having average basis weights from about 10 gsm to about 50 gsmspecifically reciting all 1 gsm increments within the above-recitedrange and all ranges formed therein or thereby.

With continued reference to FIGS. 12, 13, and 15 , the second bonds 370extend for discrete lengths along the machine direction MD and may beintermittently arranged along the machine direction MD of the firstsubstrate 306 positioned between consecutive first bonds 368. The secondbonds 370 may also be separated from each other in a cross direction CDby at least one elastic strand 316. Thus, when the first substrate 306is combined with the second substrate 308 and the elastic strands 316 toform the elastomeric laminate 302, the second bonds 370 are positionedto bond discrete regions of the first substrate 306 directly with thesecond substrate 308 without adhering the elastic strands 316 to eitherthe first substrate 306 or the second substrate 308, such as shown inFIG. 13 . It is to be appreciated that the second bonds 370 may extendcontiguously for various lengths in the cross direction CD betweenelastic strands 316. In some configurations, the second bonds 370 mayextend contiguously in the cross direction CD between and across one ormore elastic strands 316, such as shown in FIG. 13A, and as such, mayalso bond the elastics strands 316 together with the first and secondsubstrates 306, 308. In some configurations, the second bonds 370 may bedefined by one or more discrete regions of second adhesive 382 arrangedto extend in the cross direction CD and the machine direction MD betweenconsecutive first bonds 368. In some configurations, the second bonds370 may be defined by one or more regions of second adhesive 382arranged to extend continuously and contiguously in the machinedirection MD across and/or through consecutive first bonds 368. Thesecond bonds 370 may be formed with relatively low basis weights of thesecond adhesive 382. For example, in some configurations, the secondbonds 370 may include second adhesive 382 having average basis weightsfrom about 0.5 gsm to about 10 gsm specifically reciting all 1 gsmincrements within the above-recited range and all ranges formed thereinor thereby. It is to be appreciated that the first bonds 368 and/orsecond bonds 370 may define various shapes and/or sizes and maycorrespond with contours of the first substrate 306 and/or secondsubstrate 308.

As discussed above, the second bonds 370 may be arranged to bond thefirst and second substrates 306, 308 directly together without adheringthe elastic strands 316 to either substrate. As such, the second bonds370 may be configured to trap and immobilize discrete lengths of theelastic strands 316 between the second bonds 370 after the elasticstrands 316 have contracted, such as disclosed for example, in U.S. Pat.No. 6,291,039 and European Patent Publication No. EP 3 092 997 B1. Forthe purposes of a general explanation, FIG. 16A shows a length of anelastic strand 316 in a unstretched or relaxed state, wherein theelastic strand 316 defines a first cross sectional area A1. And FIG. 16Bshows a length of the elastic strand 316 from FIG. 16A in a stretchedstate, wherein the elastic strand 316 defines a second cross sectionalarea A2 that is less than the first cross sectional area A1. Thus, thecross sectional area of the stretched elastic strand 316 expands whentension is partially or fully released from the elastic strand 316.Referring now to FIG. 17A, a stretched elastic strand 316 is shownextending between adjacent second bonds 370. As shown in FIG. 17A, thesecond bonds 370 may be separated from the each other in the crossdirection CD by a distance Dsep and defining a cross sectional areaAsep. The elastic strand 316 shown in FIG. 17A is stretched and changesthe first cross sectional area A1 of the elastic strand 316 in anunstretched state to the second cross sectional area A2 of the elasticstrand in a stretched state, wherein the second cross sectional area A2is less than the cross sectional area Asep. FIG. 17B shows a detailedview of the elastic strand 316 from FIG. 17A having contracted in themachine direction MD. As shown in FIG. 17B, as the elastic strand 316contracts, the cross sectional area may increase from the second crosssectional area A2 to a third cross sectional area A3, wherein the A3 isgreater than A2. However, the discrete lengths of the contracted elasticstrand 316 positioned in the cross direction between the second bonds370 can only expand to Asep and help prevent the cross sectional area ofthe elastic strand 316 from expanding when tension on elastic strand 316has been reduced. As such, the second bonds 370 that are separated fromeach other in the cross direction CD on opposing sides of the elasticstrand 316 act to trap or immobilize discrete lengths of the contractedelastic strand 316 positioned between the second bonds 370.

The first bond applicator 372 and the second bond applicator 374 may bearranged in various ways. For example, the apparatus 300 may beconfigured such that the first substrate 306 advances past the secondbond applicator 374 before advancing to the first bond applicator 372.In some configurations, the first bond applicator 372 and the secondbond applicator 374 may be arranged to apply the first bonds 368 and thesecond bonds 370 to different substrates. For example, the first bondapplicator 372 may be arranged to apply first bonds 368 to the firstsubstrate 306, and the second bond applicator 374 may be arranged toapply second bonds 370 to the second substrate 308. The first bondapplicator 372 may also be arranged to apply first bonds 368 to thesecond substrate 308, and the second bond applicator 374 may be arrangedto apply second bonds 370 to the first substrate 306. Someconfigurations may include a plurality of first bond applicators 372,for example, wherein one first bond applicator 372 may be arranged toapply first bonds 368 to the first substrate 306 and another first bondapplicator 372 may be arranged to apply first bonds 368 to the secondsubstrate 308.

The first bond applicator 372 and the second bond applicator 374 may bealso be configured in various ways. For example, as shown in FIG. 12 ,the first bond applicator 372 may be configured as a first adhesiveapplicator device 376 that applies a first adhesive 378 to the secondsurface 340 of the first substrate 306 to form the first bonds 368. Inaddition, the second bond applicator 374 may be configured as a secondadhesive applicator device 380 that applies a second adhesive 382 to thesecond surface 340 of the first substrate 306 to form the second bonds370. It is to be appreciated that the first adhesive applicator device376 and/or the second adhesive applicator device 380 be configured as aspray nozzle and/or a slot coating device. In some configurations, thefirst adhesive applicator device 376 and/or the second adhesiveapplicator device 380 may be configured in accordance with theapparatuses and/or methods disclosed in U.S. Pat. Nos. 8,186,296;9,265,672; 9,248,054; and 9,295,590 and U.S. Patent Publication No.2014/0148773 A1.

In some configurations, the apparatus 300 may be configured such thatthe first bond applicator 372 applies the first bonds 368 to either thefirst and/or second substrates 306, 308 before the first and secondsubstrates 306, 308 are combined with the elastic strands 316. And thesecond bond applicator 374 may be configured to apply the second bonds370 to the first and second substrates 306, 308 after being combinedwith the elastic strands 316. For example, as shown in FIGS. 18-20 , thefirst substrate 306 may advance past the first bond applicator 372 thatapplies the first bonds 368 to the first substrate 306. As discussedabove, the first bond applicator 372 may be configured as a firstadhesive applicator device 376 that applies a first adhesive 378 to thesecond surface 340 of the first substrate 306 to form the first bonds368, as shown in FIGS. 14 and 18 . The first substrate 306 may thenadvance from the first bond applicator 372 to be combined with theelastic strands 316 and the second substrate 308 to form and elastomericlaminate 302, as shown in FIGS. 18 and 19 . As discussed above, thefirst bonds 368 extend for discrete lengths along the machine directionMD and may be intermittently arranged along the machine direction MD.And the first bonds 368 are positioned to bond discrete lengths of thespin finish 320 on the stretched elastic strands 316 with and betweenthe first substrate 306 and the second substrate 308, such as shown inFIGS. 19 and 20 . Referring now to FIGS. 18 and 20 , the second bondapplicator 374 applies the second bonds 370 to the combined firstsubstrate 306, second substrate 308, and elastic strands 316.

As shown in FIG. 18 , the second bond applicator 374 may be configuredas a mechanical bonding device 384 that applies the second bonds 370 inthe form of mechanical bonds, such as for example, bonds that may beapplied with heat, pressure, and/or ultrasonic devices. It is also to beappreciated that the first bond applicator 372 may be configured toapply the first bonds 368 in the form of mechanical bonds, such as forexample, bonds that may be applied with heat, pressure, and/orultrasonic devices. Examples of such mechanical bonding devices andmethods are disclosed in U.S. Pat. Nos. 4,854,984; 6,291,039; 6,248,195;8,778,127; and 9,005,392; and U.S. Patent Publication Nos. 2014/0377513A1; and 2014/0377506 A1. In addition, it is to be appreciated that thefirst bond applicator 372 and/or the second bond applicator 374 may beconfigured to operate in accordance with other bonding methods andapparatuses discussed herein and/or disclosed in the U.S. ProvisionalPatent Application No. 62/553,171, filed on Sep. 1, 2017, which isincorporated by reference herein. The second bonds 370 applied with amechanical bonder 384 also extend for discrete lengths along the machinedirection MD and may be intermittently arranged along the machinedirection MD positioned between consecutive first bonds 368. Inaddition, the second bonds 370 are also separated from each other in across direction CD by at least one elastic strand 316. Thus, the secondbonds 370 are positioned to bond discrete regions of the first substrate306 directly with the second substrate 308 without bonding the elasticstrands 316 to either the first substrate 306 or the second substrate308. The second bonds also act to trap or immobilize discrete lengths ofthe contracted elastic strand 316 positioned between the second bonds370 as discussed above with reference to FIGS. 16A-17B.

It is to be appreciated that the apparatuses 300 herein may beconfigured in various ways with various features described herein toassemble elastomeric laminates 302 having various stretchcharacteristics. For example, the apparatus 300 may be configured toassemble elastomeric laminates 302 with elastic strands 316 unwound frommore than one beam. For example, FIGS. 21 and 22 illustrate theapparatus 300 configured to assemble elastomeric laminates 302 withelastic strands 316 unwound from more than one beam 314. In particular,the apparatus 300 may include a first beam 314 a with first elasticstrands 316 a wound thereon and a second beam 314 b with second elasticstrands 316 b wound thereon. The first beam 314 a is rotatable about afirst beam rotation axis 346 a, and the second beam 314 b is rotatableabout a second beam rotation axis 346 b. During operation, as the firstbeam 314 a rotates, the first elastic strands 316 a advance in themachine direction MD from the first beam 314 a at a speed S2 with thefirst elastic strands 316 a being spaced apart from each other in thecross direction CD. From the first beam 314 a, the first elastic strands316 a advance in the machine direction MD and are joined with the firstsubstrate 306 and the second substrate 308 as discussed above.Similarly, as the second beam 314 b rotates, the second elastic strands316 b advance in the machine direction MD from the second beam 314 b ata speed S3 with the second elastic strands 316 b being spaced apart fromeach other in the cross direction CD. From the second beam 314 b, thesecond elastic strands 316 b advance in the machine direction MD and arejoined with the first substrate 306 and the second substrate 308 asdiscussed above. It is also to be appreciated that the apparatusesherein 300 may be configured to assemble elastomeric laminates 302 withelastic strands 316 unwound from one or more beams and in combinationwith elastic stands supplied from various types of elastic unwinderconfigurations, such as an overend unwinder or surface driven unwinderand unwinders such as disclosed in U.S. Pat. Nos. 6,676,054; 7,878,447;7,905,446; and 9,156,648. For example, the configuration shown in FIGS.21 and 22 and other figures and configurations herein may also includeelastic strands 316 supplied from surface and/or surface drivenunwinders. It is to be appreciated that the apparatus configurationsshown in FIGS. 21 and 22 may also include the first bond applicator 372and the second bond applicator 374 arranged to apply the first bonds 368and the second bonds 370 as discussed above. The second bond applicator374 is generically represented by a dashed-line rectangle in FIG. 21 ,and it is to be appreciated that the second bond applicator 374 may beconfigured as an adhesive applicator device 376 or a mechanical bondingdevice 384 and may be positioned to apply the second bonds 370 before orafter the first substrate 306, second substrate 308, and elastic strands316 a, 316 b are combined as discussed above.

As previously mentioned, the elastic strands 316 may be joined with thefirst and second substrates 306, 308 such that the elastomeric laminate302 may have different stretch characteristics in different regions. Forexample, with continued reference to FIGS. 21 and 22 , the elasticstrands 316 a, 316 b may be joined with the first and second substrates306, 308 such that the elastomeric laminate 302 may have differentstretch characteristics in different regions along the cross directionCD. For example, when the elastomeric laminate 302 is elongated, thefirst elastic strands 316 a may exert contraction forces in the machinedirection MD that are different from contraction forces exerted by thesecond elastic strands 316 b. Such differential stretch characteristicscan be achieved by stretching the first elastic strands 316 a more orless than the second elastic strands 316 b before joining the elasticstrands 316 a, 316 b with the first and second substrates 306, 308. Forexample, as previously discussed, the first substrate 306 and the secondsubstrate 308 may each advance at a speed S1. In some configurations,the first elastic strands 316 a may advance from the first beam 314 a atspeed S2 that is less than the speed S1, and second elastic strands 316b may advance from the second beam 314 b at the speed S3 that is lessthan the speed S1. As such, the first elastic strands 316 a and thesecond elastic strands 316 b are stretched in the machine direction MDwhen combined with the first and second substrates 306, 308. Inaddition, the speed S2 may be less than or greater than different thanthe speed S3. Thus, the first elastic strands 316 a may be stretchedmore or less than the second elastic strands 316 b when combined withthe first and second substrates 306, 308. It is also appreciated thatthe first and second elastic strands 316 a, 316 b may have variousdifferent material constructions and/or decitex values to createelastomeric laminates 302 having different stretch characteristics indifferent regions. In some configurations, the elastic laminate may haveregions where the elastic strands 316 are spaced relatively close to oneanother in the cross direction CD and other regions where the elasticstrands 316 are spaced relatively farther apart from each other in thecross direction CD to create different stretch characteristics indifferent regions. In some configurations, the elastic strands 316 maybe supplied on the beam 314 in a stretched state, and as such, may notrequire additional stretching (or may require relatively less additionalstretching) before being combined with the first substrate 306 and/orthe second substrate 308. Thus, in some configurations, the firstelastic strands 316 a may be supplied on the first beam 314 a at a firsttension, and the second elastic strands 316 b may be supplied on thesecond beam 314 b at a second tension, wherein the first tension is notequal to the second tension. In some configurations, differentialstretch characteristics in an elastomeric laminate may be created bybonding another elastomeric laminate and/or an elastic film to aparticular region of an elastomeric laminate. In some configurations,differential stretch characteristics in an elastomeric laminate may becreated by folding a portion of an elastomeric laminate onto itself in aparticular region of the elastomeric laminate.

FIG. 23 shows an arrangement of first and second rollers 324, 330 andassociated features described above with reference to FIG. 9 configuredwith the first bond applicator 372 and the second bond applicator 374arranged to apply the first bonds 368 and the second bonds 370 that maybe utilized to combine elastic strands 316, with or without a spinfinish 320, and first and second substrates 306, 308 to produce acontinuous length of elastomeric laminate 302.

In another configuration shown in FIG. 24 , the apparatus 300 may beconfigured with only the first roller 324 and without a second roller330, such as described above with reference to FIG. 10 . As such, thefirst roller 324 may be configured as the second metering device 312. Asshown in FIG. 24 , the first substrate 306 advances at speed S1 to thefirst roller 324 where the first substrate 306 partially wraps aroundthe outer circumferential surface 326 of the first roller 324. Whilepartially wrapped around the outer circumferential surface 326 of thefirst roller 324, the first substrate 306 is combined with the elasticstrands 316 and the second substrate 308. As the beam 314 rotates, theelastic strands 316 advance from the beam 314 at a speed S2 with theelastic strands 316 being spaced apart from each other in the crossdirection CD. From the beam 314, elastic strands 316 having a spinfinish 320 advance to the first roller 324 and are positioned on thesecond surface 340 of the first substrate 306. In some configurations,the speed S2 is less than the speed S1, and as such, the elastic strands316 are stretched in the machine direction MD.

With continued reference to FIG. 24 , the second substrate 308 advancesat speed S1 to the first roller 324 and partially wraps around the outercircumferential surface 326 of the first roller 324. In turn, the secondsubstrate 308 is combined with the first substrate 306 and the stretchedelastic strands 316 while on the first roller 324 such that the elasticstrands 316 are joined with the second surface 340 of the firstsubstrate 306 and the first surface 342 of the second substrate 308 toproduce a continuous length of elastomeric laminate 302.

It is to be appreciated that the apparatus configurations shown in FIGS.23 and 24 may also include the first bond applicator 372 and the secondbond applicator 374 arranged to apply the first bonds 368 and the secondbonds 370 as discussed above. It is also to be appreciated that thesecond bond applicator 374 may be configured as an adhesive applicatordevice 376 or a mechanical bonding device 384 and may be positioned toapply the second bonds 370 before or after the first substrate 306,second substrate 308, and elastic strands 316 are combined as discussedabove.

As previously mentioned, the elastomeric laminates 302 herein may beused to construct various types of absorbent article components such asdiscussed above with reference to FIGS. 1-3B. For example, theelastomeric laminates may be used to construct various types of leg cuffand/or topsheet configurations. In other examples, the elastomericlaminates may be used to construct waistbands and/or side panels intaped diaper configurations.

In yet other examples, the elastomeric laminates 302 herein may beconfigured as continuous lengths of elastomeric belt material that maybe converted into the first and second elastic belts 106, 108 discussedabove with reference to FIGS. 1-3B. As previously mentioned, the elasticmaterial 304 may correspond with the belt elastic material 168interposed between the outer layer 162 and the inner layer 164, which inturn, may correspond with either the first and/or second substrates 306,308. For example, a first continuous elastomeric laminate 302 a and asecond continuous elastomeric laminate 302 b may be combined withabsorbent chassis 102 to form diaper pants 100P. In some convertingconfigurations, such as shown in FIG. 25 , discrete absorbent chassis102 are spaced apart from each other in a machine direction MD andopposing waist regions of discrete absorbent chassis 102 are connectedwith continuous lengths of first and second continuous elastomericlaminate 302 a, 302 b. The absorbent chassis 102 may be folded to placethe first elastomeric laminate 302 a and the second elastomeric laminate302 b into a facing relationship with the each other. Next, first bonds368 may be applied to the first elastomeric laminate 302 a and thesecond elastomeric laminate 302 b, forming a continuous length ofabsorbent articles. Subsequently, the first and second elastomericlaminates 302 a, 302 b may be cut along the cross direction CD betweenadjacent first bonds 368 to form discrete diaper pants 100P. Thus, inthe configuration shown in FIG. 25 , the second bonds 370 discussedabove may be applied during the construction of the first and secondelastomeric laminates 302 a, 302 b to bond the elastic strands 316 andfirst and second substrates 306, 308 together. And the first bonds 368may be applied subsequently to the second bonds 370 to bond the firstand second elastomeric laminates 302 a, 302 b to each other. As such,the first bonds 368 may be used to create the side seams 178, 180.

In some method and apparatus configurations discussed below, discretemechanical bonds may be applied to the first substrate and the secondsubstrate to secure elastic strands therebetween, wherein the discretebonds are arranged intermittently along the machine direction. Asdiscussed in more detail below, when combining elastic strands havingrelatively low decitex values with substrates to create bonds havingcertain ranges of thicknesses, the mechanical bonds can be applied tosecure the elastic strands between substrates without severing theelastics strands and without the need for nesting grooves in amechanical bonding device. It is to be appreciated that various types ofmechanical bonding devices can be utilized with the apparatuses andmethods herein, such as for example, heated or unheated patterned andanvil rolls and/or ultrasonic bonding devices.

During the bonding process, heat and pressure are applied to the firstsubstrate and the second substrate such that malleable materials of thefirst and second substrates deform to completely surround an outerperimeter of a discrete length of the stretched elastic strand. Afterremoving the heat and pressure from the first and second substrates, themalleable materials harden to define a bond conforming with a crosssectional shape defined by the outer perimeter of the stretched elasticstrand. When the elastic strand is in a stretched state, the stretchedelastic strand defines a cross sectional area that is less than a crosssectional area of the elastic strand when in a relaxed state. Thus, whentension is released from the elastic strand, the cross sectional area ofthe elastic strand is prevented from expanding in the bond by thehardened materials of the first and second substrates, which in turn,creates forces between the elastic strand and the hardened materials.The forces between the elastic strand and the hardened materialsincreases the friction between the elastic strand and the hardenedmaterials. Thus, a frictional lock may be created between the elasticstrand and the hardened materials in the bond region by releasing thetension from the stretched elastic strands. The frictional lock holdsthe discrete length of the elastic strand in a fixed position in thebond region with the first and second substrates.

As previously mentioned, apparatuses and methods according to thepresent disclosure may be utilized to produce elastomeric laminates thatmay be used to construct various components of diapers, such as elasticbelts, leg cuffs, and the like. For example, FIGS. 26-37 show variousaspects of converting apparatuses 300 adapted to manufacture elastomericlaminates 302. As described in more detail below, the convertingapparatuses 300 operate to advance a continuous length of elasticmaterial 304, a continuous length of a first substrate 306, and acontinuous length of a second substrate 308 along a machine directionMD. The apparatus 300 stretches the elastic material 304 and joins thestretched elastic material 304 with the first and second substrates 306,308 to produce an elastomeric laminate 302. Although the elasticmaterial 304 is illustrated and referred to herein as strands, it is tobe appreciated that elastic material 304 may include one or morecontinuous lengths of elastic strands, ribbons, and/or films.

As discussed in more detail below, the converting apparatuses 300 mayinclude metering devices arranged along a process machine direction MD,wherein the metering devices may be configured to stretch the advancingelastic material and/or join stretch elastic material with one or moreadvancing substrates. In some configurations, a metering device maycomprise a beam of elastic strands wound thereon. During operation,elastic material may advance in a machine direction from a rotating beamto a downstream metering device to be joined with one or more advancingsubstrates. The elastic material advancing from the rotating beam mayinclude a spin finish, and as such, the apparatuses herein may beconfigured to bond the elastic material with the substrates withouthaving to remove the spin finish before joining the elastic materialwith the substrates. Bonds are applied to the first substrate and thesecond substrate to secure discrete lengths of the stretched elasticstrands between the first and second substrates. The discrete bonds maybe arranged intermittently along the machine direction. In someconfigurations, the bonds extend in the machine direction and may extendin a cross direction across one or more elastic strands. In someconfigurations, bonds may be separated from each other in a crossdirection. It is to be appreciated that the apparatuses and methods ofassembly of elastomeric laminates and absorbent articles describedherein and illustrated in the accompanying drawings are non-limitingexample configurations. The features illustrated or described inconnection with one non-limiting configuration may be combined with thefeatures of other non-limiting configurations. Such modifications andvariations are intended to be included within the scope of the presentdisclosure.

As shown in FIGS. 26 and 27 , a converting apparatus 300 for producingan elastomeric laminate 302 may include a first metering device 310 anda second metering device 312. The first metering device 310 may beconfigured as a beam 314 with a plurality of elastic strands 316 woundthereon. During operation, the plurality of elastic strands 316 advancein the machine direction MD from the beam 314 to the second meteringdevice 312. In addition, the plurality of elastic strands 316 may bestretched along the machine direction MD between the beam 314 and thesecond metering device 312. The stretched elastic strands 316 are alsojoined with a first substrate 306 and a second substrate 308 at thesecond metering device 312 to produce an elastomeric laminate 302. Insome configurations, one or more of the elastic strands 316 advancingfrom the beam 314 may also include a spin finish 320 located on outersurfaces of the elastics strands. In turn, stretched elastic strands 316may be connected between the first substrate 306 and the secondsubstrate 308 with bonds 388. The bonds 388 may be configured asdiscrete mechanical bonds 388 applied to the first substrate 306 and thesecond substrate 308 to secure the elastic strands 316. The discretebonds 388 may be arranged intermittently along the machine direction. Insome configurations, the bonds 388 extend in the machine direction MDand may extend in the cross direction CD across one or more elasticstrands 316. In some configurations, discrete bonds 388 may also beseparated from each other in the cross direction CD.

FIGS. 26 and 27 show an arrangement of first and second rollers 324, 330and associated features described above with reference to FIGS. 5 and 6that may be utilized to combine elastic strands 316 and first and secondsubstrates 306, 308 to produce a continuous length of elastomericlaminate 302. Although FIG. 27 shows five elastic strands 316 advancingfrom the beam 314, it is to be appreciated that the apparatuses hereinmay be configured such that more or less than five elastic strands 316advance from the beam 314.

With continued reference to FIGS. 26 and 27 , the advancing elasticstrands 316 may be joined with the first substrate 306 and the secondsubstrate 308 to form the elastomeric laminate 302. The elastic laminate302 may also advance past a bond applicator 390 configured to applybonds 388 that secure the elastic strands 316 between the firstsubstrate 306 and the second substrate 308. One or more of the elasticstrands 316 advancing from the beam 314 may include a spin finish 320.As such, the bonds 388 may be configured to secure the elastic strands316 between the first and second substrates 306, 308 without having toremove the spin finish 320 from the elastic strands 316. It is also tobe appreciated that the methods and apparatuses herein may also beconfigured to remove the spin finish 320 from the elastic strands 316.Examples of spin finish removal processes and apparatuses are describedherein and disclosed in U.S. Provisional Patent Application No.62/483,965, which is incorporated by reference herein. In addition, theelastic laminates 302 herein may be constructed with or withoutadhesives between the first and second substrates 306, 308. In addition,it is to be appreciated that the bonding methods and apparatuses hereinmay be utilized in conjunction with other bonding methods andapparatuses, such as disclosed in U.S. Patent Application No.62/553,149, filed on Sep. 1, 2017, which is incorporated by referenceherein.

As shown in FIG. 27 , the bonds 388 may extend for discrete lengthsalong the machine direction MD and may be intermittently arranged alongthe machine direction of the elastic laminate 302. Thus, the elasticstrands 316 may extend in the machine direction MD betweenintermittently spaced bond regions 402 and unbonded regions 404. It isto be appreciated that the bonds 388 may extend contiguously for variouslengths in the cross direction CD and may extend across one or moreelastic strands 316. The bonds 388 may also be separated from each otherin the cross direction CD, such as shown for example in FIG. 32 .

FIGS. 28A and 29A are detailed views of an elastic strand 316 in astretched state secured with bonds 388 between the first and secondsubstrates 306, 308. During the bonding process, the bond applicator 390may apply heat and pressure to a first region 392 of the first substrate306 and a second region 394 of the second substrate 308 such that firstmaterial 396 of the first substrate 306 and second material 398 of thesecond substrate 308 become malleable. In turn, the malleable first andsecond materials 396, 398 deform and completely surround an outerperimeter 400 of a discrete length of the stretched elastic strand 316in a bond region 402. The heat and pressure are removed from the firstregion 392 of the first substrate 306 and the second region 394 of thesecond substrate 308 as the elastic laminate 302 advances from the bondapplicator 390, and as such, the malleable first and second materials396, 398 harden in a bond 388 that conforms with a cross sectional shapedefined by the outer perimeter 400 of the stretched elastic strand 316.In some configurations, an external heat source may be used to generatethe heat used in the bonding process, such as with a heated anvil. It isalso to be appreciated that heat may be generated solely by the bondingprocess, such as for example, heat generated by an ultrasonic hornvibration or heat generated by a fusion bonding process, wherein noexternal heat source is required. In some configurations, tooling usedin the bonding process may also be chilled to help provide and/orcontrol the process temperatures at desired levels.

It is to be appreciated that the bond applicator 390 may be configuredin various ways, such as for example, heated or unheated patterned andanvil rolls and/or ultrasonic bonding devices. When configured as anultrasonic bonding device such as schematically shown in FIGS. 26 and26A, the bond applicator 390 may include a horn 391 a and may beconfigured to impart ultrasonic energy to the combined substrates 306,308 and elastic strands 316 on an anvil 391 b. In turn, the anvil 391 bmay include a plurality of pattern elements 391 c protruding radiallyoutward from the anvil 391 b, wherein each pattern element includes apattern surface 391 d. It is to be appreciated that the number, size,and shape of some or all the pattern surfaces and/or pattern elementsmay be different. In some embodiments, the shape and size of the patternsurface 391 d of each pattern element 391 c may be identical orsubstantially identical to each other. In some configurations, thepattern elements 391 c and/or pattern surfaces 391 d may have aperimeter that defines circular, square, rectangular, elliptical, andvarious types of other shapes. In some configurations, the anvil 391 bmay include a pattern element 391 c with a pattern surface 391 d thatdefines a continuous crossing line pattern and/or various other shapes,such as disclosed in U.S. Pat. No. 9,265,672, which is incorporated byreference herein. It is to be appreciated that the pattern surface 391d, such as discussed above, may be flat and/or may also include regionsdefined by relatively high and relatively low elevations. Thus, suchpattern surfaces may create bonds 388 having varying thicknesses acrossthe bond region 402. In addition, it is to be appreciated that anelastic strand 316 may extend across such relatively high and lowelevations during the bonding process. It is to be appreciated that thechoice of pattern surface shape may enable the creation of uniquetextures and patterns where the location and size of the bonding sitesimpact local buckling resistance of a nonwoven laminate and may createdesired homogeneous textures upon relaxation of the elastics and theresulting nonwoven corrugation.

With continued reference to FIGS. 26 and 26A, the ultrasonic bondingdevice may apply energy to the horn 391 a to create resonance of thehorn at frequencies and amplitudes so the horn vibrates rapidly in adirection generally perpendicular to the substrates 306, 308 and elasticstrands 316 being advanced past the horn 391 a on the anvil 391 b.Vibration of the horn 391 a generates heat to melt and bond thesubstrates 306, 308 together in areas supported by the pattern elements391 c on the anvil 391 b. Thus, the bonds 388 and/or bond regions 402may have shapes that correspond with and may mirror shapes of thepattern surfaces 391 d. As shown in FIG. 26A, the pattern surface 391 dmay extend contiguously across one or more elastic strands 316positioned between the first substrate 306, and the second substrate308. It is to be appreciated that aspects of the ultrasonic bondingdevices may be configured in various ways, such as for example linear orrotary type configurations, and such as disclosed for example in U.S.Pat. Nos. 3,113,225; 3,562,041; 3,733,238; 5,110,403; 6,036,796;6,508,641; and 6,645,330. In some configurations, the ultrasonic bondingdevice may be configured as a linear oscillating type sonotrode, such asfor example, available from Herrmann Ultrasonic, Inc. In someconfigurations, the sonotrode may include a plurality of sonotrodesnested together in the cross direction CD. The bond applicator 390 mayalso be configured in various other ways, such as for example, themechanical bonding devices and methods disclosed in U.S. Pat. Nos.4,854,984; 6,248,195; 8,778,127; and 9,005,392; and U.S. PatentPublication Nos. 2014/0377513 A1; and 2014/0377506 A1. Although the bondapplicator 390 is shown in FIGS. 26 and 27 as a separate device that ispositioned downstream of the second metering device 312, it is to beappreciated the second metering device 312 may also be configured as thebond applicator 390. As such, the first substrate 306, second substrate308, and elastic strands 316 may be combined and bonded together at thebond applicator 390 to form the elastic laminate 302.

As previously mentioned, a frictional lock may be applied between aportion of the elastic strand 316 and the hardened first and secondmaterials 396, 398 by releasing tension from the stretched elasticstrand 316. The frictional lock acts to hold and/or secure the elasticstrand 316 in a fixed position in the bond region 402. For the purposesof a general explanation, FIG. 16A shows a length of an elastic strand316 in a unstretched or relaxed state, wherein the elastic strand 316defines a first cross sectional area A1. And FIG. 16B shows a length ofthe elastic strand 316 from FIG. 16A in a stretched state, wherein theelastic strand 316 defines a second cross sectional area A2 that is lessthan the first cross sectional area A1. Thus, the cross sectional areaof the stretched elastic strand 316 expands when tension is partially orfully released from the elastic strand 316. As discussed in more detailbelow, the tendency of the cross sectional area of the elastic strand316 to expand helps create the frictional lock.

Turning next to FIG. 28B, a detailed view of an elastic strand 316, suchas shown in FIG. 28A, is provided wherein tension has been released (orreduced) on the elastic strand 316 and showing how the tendency of theelastic strand 316 to expand creates a frictional lock in the bondedregion 402. FIGS. 28B and 29B show the elastic strand 316 as having afirst cross sectional area A1 in an unbonded region 404 of the elasticlaminate 302, wherein the first cross sectional area A1 is greater thanthe second cross sectional area A2 of the stretched elastic strand 316shown in FIGS. 28A and 29A. And FIGS. 28D and 29C show the elasticstrand 316 as having a third cross sectional area A3 in the bond region402 of the elastic laminate 302, wherein the third cross sectional areaA3 is the same or about the same as the second cross sectional area A2of the stretched elastic strand 316 shown in FIGS. 28A and 29A. As shownin FIG. 29C, the hardened first and second materials 396, 398 in thebond region 402 help prevent the cross sectional area of the elasticstrand 316 from expanding when tension has on elastic strand 316 hasbeen reduced. The tendency of the elastic strand 316 to expand createsforces F (represented by dashed double arrow lines in FIG. 29C) exertedbetween the hardened first and second materials 396, 398 in the bondregion 402. In turn, the forces F between the elastic strand 316 and thehardened first and second materials 396, 398 creates a frictional lockby increasing the friction forces between the elastic strand 316 and thehardened materials 396, 398. The increased friction forces in themachine direction MD along the length of the elastic strand 316 in thebond region 402 holds the discrete length of the elastic strand 316 in afixed position in the bond region 402 together with the first and secondsubstrates 306, 308. As such, in some configurations, no adhesive may beapplied to and/or present between the elastic strand 316 and thehardened materials 396, 398. It is also to be appreciated that in someconfigurations, adhesive may be applied to and/or present between theelastic strand 316 and the hardened materials 396, 398 to help thefrictional lock hold the discrete length of the elastic strand 316 in afixed position in the bond region 402 together with the first and secondsubstrates 306, 308. In some configurations, adhesive and the frictionallock in the bond regions 402 may share the load exerted by elasticstrand 316. In some configurations, adhesive positioned on the elasticstrand 316 may increase the coefficient of friction between the elasticstrand 316 and the hardened materials 396, 398 in the bond region 402.It is to be appreciated that various quantities of adhesive may bepresent in the bond regions 402, such as for example, about 10 gsm orless.

It is also to be appreciated that the elastic strands 316 herein bondedin accordance with the methods described herein may also be constructedfrom one or more filaments 406. For example, FIG. 30A shows a crosssectional view of an elastic strand 316 in a bond region 402 wherein theelastic strand 316 comprises a plurality of individual filaments 406. Asshown in FIG. 30A, the elastics strand 316 includes outer filaments 406a surrounding an inner filament 406 b. The outer filaments 406 a definethe outer perimeter 400 of the elastic strand 316, and the outerfilaments 406 a may surround the inner filament 406 b such that theinner filament 406 b is not in contact with the hardened first material396 and the hardened second material 398 in the bond 388. It is to beappreciated that the filaments 406 may be arranged in various positionswithin the bond region 402. For example, FIG. 30B shows a crosssectional view of an elastic strand 316 in a bond region 402 wherein theplurality of individual filaments 406 together define a perimeter 400that is elongated along the cross direction CD, and wherein all of theplurality of filaments 406 are in contact with hardened first material396 and hardened second material 398. In another example, FIG. 30C showsa cross sectional view of an elastic strand 316 in a bond region 402wherein at least two of the filaments 406 are separated from each otherby at least one of hardened first material 396 and hardened secondmaterial 398. It is to be appreciated that the elastic strand 316 may beconstructed to allow for more or less separation of filaments 406 duringthe bonding operations herein. For example, in some elastic strandassembly configurations, a cooling operation, such as a manipulatingtwisting jet of air, may be utilized to modify adhesion properties ofthe filaments to desired levels. It is also to be appreciated that thestrands 316 and/or filaments 406 herein may define various differentcross-sectional shapes. For example, in some configurations, strands 316or filaments 406 may define circular, oval, or elliptical crosssectional shapes or irregular shapes, such as dog bone and hourglassshapes.

As previously mentioned, substrates 306, 308 with elastic strands 316positioned therebetween can be bonded in accordance with methods hereinwithout severing the elastics strands and without the need for nestinggrooves in bond applicator 390. For example, as shown in FIGS. 29C and30A-30C, heat and pressure may be applied to the substrates 306, 308 tocreate bonds 388 surrounding the elastic strand 316. The bond 388 isdefined by hardened first material 396 and hardened second material 398and has a minimum thickness Tb. In addition, the elastic strand 316 mayhave a thickness Te in the bond region 402. In some configurations,substrates 306, 308 that are bonded together to create a bond thicknessTb having a certain size relative to the elastic strand thickness Te,the elastic strand 316 may not be severed during the bonding process. Inaddition, the forces F exerted between the elastic strand 316 and thehardened first and second materials 396, 398 in the bond region 402 maybe prevented from breaking the bond 388. Such a relationship between Teand Tb may be characterized by the decitex of elastic strands 316 andthe bond thickness Tb. For example, substrates 306, 308 may be bondedtogether with an elastic strand having a decitex value less than orequal to about 70 positioned therebetween to create a bond 388 having athickness Tb of at least about 100 μm (“microns”) without severing theelastic strand 316. In another example, substrates 306, 308 may bebonded together with an elastic strand having a decitex value less thanor equal to about 250 positioned therebetween to create a bond 388having a thickness Tb of at least about 200 μm (“microns”) withoutsevering the elastic strand 316. In some configurations, such as shownin FIG. 30C, the bond thickness Tb may be at least 50% larger than theminimum cross sectional thickness Tf a filament 406. For example, asshown in FIG. 30C, the minimum cross sectional thickness Tf of afilament 406 having a circular cross section may be defined the diameterof such a filament.

FIGS. 30D-30F are electron microscope photographs (“SEM”) showing crosssectional views of an elastic strand 316 in a bond region 402 surroundedby hardened first and second materials 396, 398 from two nonwovens. InFIGS. 30D and 30E, the elastic strand 316 is a 70 decitex elastic strandincluding five filaments 406, wherein each filament 406 has a diameterof about 43 μm (“microns”). And the bond 388 defines a thickness Tb ofabout 80 μm (“microns”). In FIG. 30F, the elastic strand 316 is a 235decitex elastic strand including fifteen filaments 406, wherein eachfilament 406 has a diameter of about 43 μm (“microns”). And the bond 388defines a thickness Tb of about 200 μm (“microns”).

As previously mentioned, it is to be appreciated that the apparatuses300 herein may be configured in various ways with various featuresdescribed herein to assemble elastomeric laminates 302 having variousstretch characteristics. In addition, the apparatuses 300 herein may beconfigured in various ways with various features described herein toassemble elastomeric laminates 302 having various stretchcharacteristics. For example, the apparatus 300 may be configured toassemble elastomeric laminates 302 with elastic strands 316 unwound frommore than one beam and/or in combination with elastic stands suppliedfrom various types of elastic unwinder configurations, such as anoverend unwinder or surface driven unwinder and unwinders such asdisclosed in U.S. Pat. Nos. 6,676,054; 7,878,447; 7,905,446; and9,156,648. For example, FIGS. 31 and 32 illustrate the apparatus 300configured to assemble elastomeric laminates 302 with elastic strands316 unwound from more than one beam 314. In particular, the apparatus300 may include a first beam 314 a with first elastic strands 316 awound thereon and a second beam 314 b with second elastic strands 316 bwound thereon. The first beam 314 a is rotatable about a first beamrotation axis 346 a, and the second beam 314 b is rotatable about asecond beam rotation axis 346 b. During operation, as the first beam 314a rotates, the first elastic strands 316 a advance in the machinedirection MD from the first beam 314 a at a speed S2 with the firstelastic strands 316 a being spaced apart from each other in the crossdirection CD. From the first beam 314 a, the first elastic strands 316 aadvance in the machine direction MD and are joined with the firstsubstrate 306 and the second substrate 308 as discussed above.Similarly, as the second beam 314 b rotates, the second elastic strands316 b advance in the machine direction MD from the second beam 314 b ata speed S3 with the second elastic strands 316 b being spaced apart fromeach other in the cross direction CD. From the second beam 314 b, thesecond elastic strands 316 b advance in the machine direction MD and arejoined with the first substrate 306 and the second substrate 308 asdiscussed above. It is also to be appreciated that the apparatusconfiguration shown in FIGS. 31 and 32 may also include the bondapplicator 390 arranged to apply the bonds 388 as discussed above. Thebond applicator 390 is generically represented by a dashed-linerectangle in FIG. 31 .

As previously mentioned, the elastic strands 316 may be joined with thefirst and second substrates 306, 308 such that the elastomeric laminate302 may have different stretch characteristics in different regions. Forexample, with continued reference to FIGS. 31 and 32 , the elasticstrands 316 a, 316 b may be joined with the first and second substrates306, 308 such that the elastomeric laminate 302 may have differentstretch characteristics in different regions along the cross directionCD, such as discussed above with reference to FIGS. 21 and 22 .

FIG. 33 shows an arrangement of first and second rollers 324, 330 andassociated features described above with reference to FIG. 9 configuredwith the bond applicator 390 arranged to apply the bonds 388 that may beutilized to combine elastic strands 316 and first and second substrates306, 308 to produce a continuous length of elastomeric laminate 302.

In another configuration shown in FIG. 34 , the apparatus 300 may beconfigured with only the first roller 324 and without a second roller330, such as described above with reference to FIG. 10 . As such, thefirst roller 324 may be configured as the second metering device 312. Inaddition, the first roller 324 may also be configured as a component ofthe bond applicator 390. As shown in FIG. 34 , the first substrate 306advances at speed S1 to the first roller 324 where the first substrate306 partially wraps around the outer circumferential surface 326 of thefirst roller 324. While partially wrapped around the outercircumferential surface 326 of the first roller 324, the first substrate306 is combined with the elastic strands 316 and the second substrate308. As the beam 314 rotates, the elastic strands 316 advance from thebeam 314 at a speed S2 with the elastic strands 316 being spaced apartfrom each other in the cross direction CD. From the beam 314, elasticstrands 316 advance to the first roller 324 and are positioned on thesecond surface 340 of the first substrate 306. In some configurations,the speed S2 is less than the speed S1, and as such, the elastic strands316 are stretched in the machine direction MD. With continued referenceto FIG. 34 , the second substrate 308 advances at speed S1 to the firstroller 324 and partially wraps around the outer circumferential surface326 of the first roller 324. In turn, the second substrate 308 iscombined with the first substrate 306 and the stretched elastic strands316 while on the first roller 324 such that the elastic strands 316 arejoined with the second surface 340 of the first substrate 306 and thefirst surface 342 of the second substrate 308 to produce a continuouslength of elastomeric laminate 302. In addition, the bond applicator 390may be configured to apply the bonds 388 before elastic laminate 302advances from the first roller 324.

In some configurations, the speed S2 is less than the speed S1, and assuch, the elastic strands 316 are stretched in the machine direction MD.With continued reference to FIG. 34 , the second substrate 308 advancesat speed S1 to the first roller 324 and partially wraps around the outercircumferential surface 326 of the first roller 324. In turn, the secondsubstrate 308 is combined with the first substrate 306 and the stretchedelastic strands 316 while on the first roller 324 such that the elasticstrands 316 are joined with the second surface 340 of the firstsubstrate 306 and the first surface 342 of the second substrate 308 toproduce a continuous length of elastomeric laminate 302. In addition,the bond applicator 390 may be configured to apply the bonds 388 beforeelastic laminate 302 advances from the first roller 324.

As previously mentioned, it is also to be appreciated that in someconfigurations, the first substrate and second substrate 306, 308 hereinmay be defined by two discrete substrates or may be defined by foldedportions of a single substrate. For example, as shown in FIG. 35 , thefirst substrate 306 advances at speed S1 to the first roller 324 wherethe first substrate 306 partially wraps around the outer circumferentialsurface 326 of the first roller 324. While partially wrapped around theouter circumferential surface 326 of the first roller 324, the firstsubstrate 306 is combined with the elastic strands 316. As the beam 314rotates, the elastic strands 316 advance from the beam 314 at a speed S2with the elastic strands 316 being spaced apart from each other in thecross direction CD. From the beam 314, elastic strands 316 advance tothe first roller 324 and are positioned on the second surface 340 of thefirst substrate 306. As shown in FIGS. 35 and 36 , a folding device 368may operate to fold a first portion 306 a onto a second portion 306 b ofthe first substrate with the elastic strands 316 positioned between thefirst and second portions 306 a, 306 b to create the elastic laminate302. As shown in FIGS. 35 and 37 , the bond applicator 390 may beconfigured to apply the bonds 388 before elastic laminate 302 advancesfrom the first roller 324.

In some configurations discussed below, methods and apparatuses may beconfigured to make elastomeric laminates with deactivated regions thatmay be used as components of absorbent articles. The methods andapparatuses according to the present disclosure may be configured with apattern roll and a pressing surface adjacent the pattern roll. Thepattern roll may be adapted to rotate about an axis of rotationextending axially in a cross direction, and the pressing surface may beconfigured as an energy transfer surface of an ultrasonic horn. Thepattern roll may include a bonding surface and discrete first channelsin the bonding surface, wherein the discrete first channels arecircumferentially spaced apart from each other. The pattern roll mayalso include a protuberance extending axially in the cross directionbetween two of the discrete first channels. As discussed in more detailbelow, the assembly process utilizes elastic strands that define a firstcross sectional area in an unstretched state, and the elastic strandsare stretched to define a second cross sectional area that is less thanthe first cross sectional area. The first and second substrates with thestretched elastic strands therebetween advance in a machine direction onthe pattern roll, wherein stretched elastic strands extend through thediscrete first channels. As the pattern roll rotates, the firstsubstrate and the second substrate are welded together between thebonding surface and the pressing surface to create bonds between thefirst and second substrates. The bonds are separated from each other inthe cross direction by the stretched elastic strands positioned inrespective discrete first channels to form first sleeves surrounding thestretched elastic strands. The first sleeves may each define a crosssectional area that is less than the first cross sectional area andequal to or greater than the second cross sectional area. As the patternroll continues to rotate, the first substrate, the second substrate, andone or more stretched elastic strands are compressed between thepressing surface and the protuberance to sever the one or more stretchedelastic strands to create deactivated regions in the elastomericlaminate. In turn, the one or more severed elastic strands retract andexpand to create a frictional lock between the first sleeves and the oneor more severed elastic strands. As such, the frictional lock preventsthe severed elastic strand from continuing to retract.

As discussed in more detail below, the processes and apparatuses hereinmay also be configured to help prevent ends of the severed elasticstrands from snapping back or retracting in an uncontrolled fashion. Forexample, during the assembly process, the first substrate, the secondsubstrate, and the stretched elastic strands may be wrapped on therotating pattern roll. In turn, tension exerted on the first and secondsubstrates force the substrates against the pattern roll, and thus, mayhelp to press and hold the stretched elastic strands in position betweenthe first and second substrates. Thus, as the stretched elastic strandsare severed, the ends of the severed elastic strands may tend to retractor snap back at a relatively slower and/or controlled rate. In someconfigurations, the pattern roll may include second discrete channelsthat may be circumferentially positioned between first discrete channelsand/or between first discrete channels and the protuberance. Thediscrete second channels may also be wider and and/or deeper than thefirst discrete channels. As the pattern roll rotates, the firstsubstrate and the second substrate are welded together between thebonding surface and the pressing surface to create bonds between thefirst and second substrates, wherein the bonds are separated from eachother in the cross direction by the stretched elastic strands positionedin respective second channels to form second sleeves surrounding thestretched elastic strands. The second sleeves may each define a crosssectional area that is greater than the cross sectional area of a firstsleeve. Thus, the ends of the severed elastic strands may retractthrough the second sleeves while at the same time being guided along themachine direction by the second sleeves while retracting.

As previously mentioned, apparatuses and methods according to thepresent disclosure may be utilized to produce elastomeric laminates thatmay be used to construct various types of absorbent article components,such as elastic belts, leg cuffs, and the like. For example, FIGS. 38-49show various aspects of converting apparatuses 300 adapted tomanufacture elastomeric laminates 302. As described in more detailbelow, the converting apparatuses 300 operate to advance a continuouslength of elastic material 304, a continuous length of a first substrate306, and a continuous length of a second substrate 308 along a machinedirection MD. It is also to be appreciated that in some configurations,the first substrate and second substrate 306, 308 herein may be definedby two discrete substrates or may be defined by folded portions of asingle substrate. The apparatus 300 stretches the elastic material 304and joins the stretched elastic material 304 with the first and secondsubstrates 306, 308 to produce an elastomeric laminate 302. Although theelastic material 304 is illustrated and referred to herein as strands316, it is to be appreciated that elastic material 304 may include oneor more continuous lengths of elastic strands, ribbons, and/or films.

As discussed in more detail below, the converting apparatuses 300 mayinclude metering devices arranged along a process machine direction MD,wherein the metering devices may be configured to stretch the advancingelastic material and/or join stretch elastic material with one or moreadvancing substrates. In some configurations, an upstream meteringdevice may comprise an overend unwind device and/or a beam of elasticstrands wound thereon. During operation, elastic material may advance ina machine direction from an upstream metering device to a downstreammetering device to be joined with one or more advancing substrates toform an elastomeric laminate. The elastomeric laminate is partiallywrapped onto a pattern roll adjacent a pressing surface. The patternroll rotates and advances the elastomeric laminate between the patternroll and the pressing surface, wherein bonds are applied to the firstsubstrate and the second substrate to secure discrete lengths of thestretched elastic strands between the first and second substrates. Thediscrete bonds may be arranged intermittently along the machinedirection. In some configurations, bonds may be separated from eachother in a cross direction by an elastic strand. The pattern roll andpressing surface also operate to remove the elasticity of discreteregions of the elastomeric laminate by cutting one or more elasticstrands in the discrete regions. It is to be appreciated that theapparatuses and methods of assembly of elastomeric laminates andabsorbent articles described herein and illustrated in the accompanyingdrawings are non-limiting example configurations. The featuresillustrated or described in connection with one non-limitingconfiguration may be combined with the features of other non-limitingconfigurations. Such modifications and variations are intended to beincluded within the scope of the present disclosure.

As shown in FIGS. 38 and 39 , a converting apparatus 300 for producingan elastomeric laminate 302 may include a first metering device 310 anda second metering device 312. The first metering device 310 may beconfigured as a beam 314 with a plurality of elastic strands 316 woundthereon. During operation, the plurality of elastic strands 316 advancein the machine direction MD from the beam 314 to the second meteringdevice 312. In addition, the plurality of elastic strands 316 may bestretched along the machine direction MD between the beam 314 and thesecond metering device 312. The stretched elastic strands 316 are alsojoined with a first substrate 306 and a second substrate 308 at thesecond metering device 312 to produce an elastomeric laminate 302. Insome configurations, one or more of the elastic strands 316 advancingfrom the beam 314 may also include a spin finish 320 located on outersurfaces of the elastics strands.

As discussed above, the elastic strands 316 advancing from the rotatingbeam 314 may also include a spin finish 320, and as such, theapparatuses herein may be configured to bond the elastic strands 316between the substrates 306, 308 without having to remove the spin finish320 before joining the elastic strands 316 with the substrates 306, 308.It is also to be appreciated that the methods and apparatuses herein mayalso be configured to remove the spin finish 320 from the elasticstrands 316. Examples of spin finish removal processes and apparatusesare discussed herein and are disclosed in U.S. Provisional PatentApplication No. 62/483,965, which is incorporated by reference herein.In addition, the elastomeric laminates 302 herein may be constructedwith or without adhesives between the first and second substrates 306,308. In addition, it is to be appreciated that the bonding methods andapparatuses herein may be utilized in conjunction with other bondingmethods and apparatuses disclosed here and as disclosed in U.S. PatentApplication Nos. 62/436,589; 62/553,149; and 62/553,171, which areincorporated by reference herein. Although the elastomeric laminateassembly process may utilize elastic strands supplied from a beam, it isto be appreciated that elastic strands may also be supplied with varioustypes of elastic unwinder configurations, such as disclosed in U.S. Pat.Nos. 6,676,054; 7,878,447; 7,905,446; and 9,156,648, all of which areincorporated by reference herein.

FIGS. 38 and 39 show an arrangement of first and second rollers 324, 330and associated features described above with reference to FIGS. 5 and 6that may be utilized to combine elastic strands 316 and first and secondsubstrates 306, 308 to produce a continuous length of elastomericlaminate 302. Although FIG. 39 shows fourteen elastic strands 316advancing from the beam 314, it is to be appreciated that theapparatuses herein may be configured such that more or less thanfourteen elastic strands 316 advance from the beam 314.

With continued reference to FIGS. 38 and 39 , the advancing elasticstrands 316 may be joined with the first substrate 306 and the secondsubstrate 308 to form the elastomeric laminate 302. The elastomericlaminate 302 may also advance to a bond applicator 500 configured toapply bonds 408 that secure the elastic strands 316 between the firstsubstrate 306 and the second substrate 308. The bond applicator 500 mayalso be configured to intermittently sever one or more stretched elasticstrands 316 to create deactivated regions 410 in the elastomericlaminate 302. As shown in FIG. 39 , the deactivated regions 410 may beintermittently spaced between elastomeric regions 412 along the machinedirection MD. For the purposes of clarity, dashed lines 414 are shown inFIG. 39 to represent example boundaries between the deactivated regions410 and the elastomeric regions 412. It is to be appreciated that suchboundaries between the deactivated regions 410 and the elastomericregions 412 can also be curved, angled, and/or straight.

It is to be appreciated that the bond applicator 500 may be configuredin various ways, such as with heated or unheated patterned and anvilrolls and/or ultrasonic bonding devices. For example, the bondapplicator 500 schematically shown in FIGS. 38 and 39 may include apattern roll 502 and pressing surface 504 adjacent the pattern roll 502.The pattern roll 502 may be adapted to rotate about an axis of rotation506 extending axially in the cross direction CD. During operation, theelastomeric laminate 302 may be partially wrapped onto the pattern roll502. And the pattern roll 502 rotates about the axis of rotation 506 toadvance the elastomeric laminate 302 through a nip 508 between thepattern roll 502 and the pressing surface 504. As shown in FIG. 38 , thebond applicator 500 may also include one or more rolls 503 that helpguide the elastomeric laminate to and from the pattern roll 502. Thepattern roll 502 may also comprise one or more bonding surfaces 510defined by one or more bonding elements 512 extending radially outwardfrom an outer circumferential surface 514. The pattern roll 502 may alsocomprise a protuberance 516 extending radially outward from the outercircumferential surface 514. As discussed in more detail below, theelastomeric laminate 302 is advanced between the bonding surface 510 andthe pressing surface 504 to weld the first substrate 306 and the secondsubstrate 308 together to create bonds 408 between the first substrate306 and the second substrate 308. And the elastomeric laminate 302 isadvanced between the protuberance 516 and the pressing surface 504 tosever one or more elastic strands 316. Thus, as the elastomeric laminate302 advances through the nip 508, the first substrate 306 and the secondsubstrate 308 are welded together and one or more elastic strands 316are intermittently severed to create deactivated regions 410 in theelastomeric laminate 302.

As discussed above, during the assembly operation, the elastomericlaminate 302 may be partially wrapped onto the pattern roll 502. Asshown in FIG. 38 , the extent that the elastomeric laminate 302 wrapsaround the pattern roll 502 is referred to herein as the wrap angle, θ,and may be expressed in units of degrees. In some configurations, thewrap angle, θ, may be greater than zero degrees and less than or equalto 180 degrees, specifically reciting all 1 degree increments within theabove-recited range and all ranges formed therein or thereby. In someconfigurations, the wrap angle, θ, may be greater 180 degrees.

It is to be appreciated that the pressing surface 504 may be configuredin various ways. For example, as shown in FIG. 38 , the pressing surface504 may comprise an energy transfer surface of an ultrasonic bondingdevice 518. As such, the bond applicator 500 may include a horn 520 andmay be configured to impart ultrasonic energy to the combined substrates306, 308 and elastic strands 316 on the pattern roll 502. The ultrasonicbonding device 518 may apply energy to the horn 520 to create resonanceof the horn 520 at frequencies and amplitudes so the horn vibratesrapidly in a direction generally perpendicular to the substrates 306,308 and elastic strands 316 being advanced past the horn 520 on thepattern roll 502. Vibration of the horn 520 creates bonds 408 and/orbond regions 416 by generating heat to melt and bond the substrates 306,308 together in areas supported by the bonding surface 510 on thepattern roll 502. Thus, the bonds 408 and/or bond regions 416 may haveshapes that correspond with and may mirror shape of the bonding surfaces510.

It is to be appreciated that aspects of the ultrasonic bonding devices518 may be configured in various ways, such as for example linear orrotary type configurations, and such as disclosed for example in U.S.Pat. Nos. 3,113,225; 3,562,041; 3,733,238; 5,110,403; 6,036,796;6,508,641; and 6,645,330. In some configurations, the ultrasonic bondingdevice 518 may be configured as a linear oscillating type sonotrode,such as for example, available from Herrmann Ultrasonic, Inc. In someconfigurations, the sonotrode may include a plurality of sonotrodesnested together in the cross direction CD.

Although the bond applicator 500 is shown in FIGS. 38 and 39 as aseparate device that is positioned downstream of the second meteringdevice 312, it is to be appreciated that the second metering device 312may also be configured as the bond applicator 500. As such, the firstsubstrate 306, second substrate 308, and elastic strands 316 may becombined and bonded together at the bond applicator 500 to form theelastomeric laminate 302.

It is to be appreciated that the apparatuses and methods herein may beconfigured to create various configurations of bonds 408 in theelastomeric laminate 302. For example, as previously mentioned, thepattern roll 502 may include one or more bonding elements 512 protrudingradially outward from the pattern roll 502, wherein each bonding element512 includes a bonding surface 510, such as shown for example in FIGS.40 and 41 . It is to be appreciated that the number, size, and shape ofsome or all the bonding surfaces 510 and/or bonding elements 512 may bedifferent. In some embodiments, the shape and size of the bondingsurface 510 of each bonding element 512 may be identical orsubstantially identical to each other. In some configurations, thebonding elements 512 and/or bonding surfaces 510 may have a perimeterthat defines circular, square, rectangular, elliptical, and varioustypes of other shapes. In some configurations, the pattern roll 502 mayinclude a bonding element 512 with a bonding surface 510 that defines acontinuous crossing line pattern and/or various other shapes, such asdisclosed in U.S. Pat. No. 9,265,672, which is incorporated by referenceherein. It is to be appreciated that the bonding surface 510, such asdiscussed above, may be flat and/or may also include regions defined byrelatively high and relatively low elevations. Thus, such bondingsurfaces 510 may create bonds 408 having varying thicknesses across thebond region 416.

With continued reference to FIGS. 40 and 41 , the pattern roll 502 mayalso include discrete channels 522 in the bonding surfaces 510. Duringoperation, the first substrate 306 and the second substrate 308 with thestretched elastic strands 316 therebetween may be advanced onto thepattern roll 502, wherein the stretched elastic strands 316 are alignedwith and extend through respective channels 522, such as shown in FIG.39A. As the pattern roll 502 rotates, the first substrate 306 and thesecond substrate 308 are welded together between the bonding surfaces510 and the pressing surface 504 to create bonds 408 between the firstsubstrate 306 and the second substrate 308. As discussed below in moredetail with reference to FIGS. 43A-43B, the bonds 408 are separated fromeach other in the cross direction CD by the stretched elastic strands316 positioned in the channels 522 to form sleeves 418 that surround thestretched elastic strands 316. The inner perimeter of the sleeves 418may be defined by the first substrate 306, the second substrate 308, andthe bonds 408 on opposing sides of the elastic strand 316.

As shown in FIGS. 41, 41A, and 41B, the pattern roll 502 may includefirst channels 522 a and second channels 522 b, wherein the first andsecond channels 522 a, 522 b may be configured to create sleeves 418having different sizes. As shown in FIGS. 42A and 42B, the bondingsurfaces 510 may be positioned at a first radial distance R1 from theaxis of rotation 506. Discrete first channels 522 a may be positioned inthe bonding surfaces 510 so as to be spaced apart from each othercircumferentially and in the cross direction CD. In addition, the firstchannels 522 a may comprise a first width W1 extending axially along theaxis of rotation 506 and may comprise a first depth D1 extendingradially inward from the bonding surface 510. Discrete second channels522 b may also be positioned in the bonding surfaces 510 so as to bespaced apart from each other circumferentially and in the crossdirection CD. The second channels 522 b may comprise a second width W2extending axially along the axis of rotation 506 and may comprise asecond depth D2 extending radially inward from the bonding surface 510.In some configurations, the second width W2 may be greater than thefirst width W1 and/or the second depth D2 may be greater than the firstdepth D1. In turn, the first channels 522 a may be configured to createfirst sleeves 418 a that are sized to secure discrete lengths of theelastic strands 316 in fixed positions with a frictional lock betweenthe first and second substrates 306, 308. In addition, the secondchannels 522 b may be configured to create second sleeves 418 b that aresized to allow the elastic strands 316 to move relative to the first andsecond substrates 306, 308 as the elastic strands 316 stretch andcontract along machine direction MD while at the same time holdingand/or guiding the elastic strands 316 in desired positions along thecross direction CD.

As previously mentioned, the pattern roll 502 may include first channels522 a that are sized to create first sleeves 418 a that surrounddiscrete lengths of stretched elastic strands 316. In turn, a frictionallock may be applied between a portion of the elastic strand 316 and thefirst sleeves 418 a by releasing tension from the stretched elasticstrand 316. The frictional lock acts to hold and/or secure a portion ofthe elastic strand 316 in a fixed position relative to the first andsecond substrates 306, 308. For the purposes of a general explanation,FIG. 16A shows a length of an elastic strand 316 in a unstretched orrelaxed state, wherein the elastic strand 316 defines a first crosssectional area A1. And FIG. 16B shows a length of the elastic strand 316from FIG. 16A in a stretched state, wherein the elastic strand 316defines a second cross sectional area A2 that is less than the firstcross sectional area A1. Thus, the cross sectional area of the stretchedelastic strand 316 expands when tension is partially or fully releasedfrom the stretched elastic strand 316. As discussed in more detailbelow, the tendency of the cross sectional area of the elastic strand316 to expand helps create the frictional lock.

FIGS. 43A and 44A are detailed views of an elastic strand 316, such asshown in FIG. 39 , in a stretched state extending in the machinedirection between the first and second substrates 306, 308. During thebonding process, the bond applicator 500 may apply heat and pressure toregions of the first substrate 306 and the second substrate 308 to weldthe first and second substrates 306, 308 together with bonds 408. Thebonds 408 may be separated from each other in the cross direction CD bythe stretched elastic strand 316. In turn, the bonds 408 form sleeves418 that surround the stretched elastic strands 316. As shown in FIG.44A, the inner perimeter of the sleeves 418 may be defined by the firstsubstrate 306, the second substrate 308, and the bonds 408 on opposingsides of the elastic strand 316. As discussed above, the first channels522 a in the pattern roll 502 may be configured to create first sleeves418 a to secure discrete lengths of the elastic strands 316 in fixedpositions with a frictional lock between the first and second substrates306, 308. For example, the elastic strand 316 shown in FIGS. 43A and 44Amay define a second cross sectional area A2 in a stretched state. Theelastic strand 316 may also define a first cross sectional area A1 in arelaxed state, wherein A2 is less than A1. In turn, the first sleeves418 a may define a third cross sectional area A3 that may be greaterthan or equal to A2, and wherein A3 may be less than A1.

Turning next to FIGS. 43B and 44B, a detailed view of an elastic strand316, such as shown in FIGS. 43A and 44A, is provided wherein tension hasbeen released (or reduced) on the elastic strand 316 and showing how thetendency of the elastic strand 316 to expand creates a frictional lockin the bonded region 416. As shown in FIG. 44B, the first sleeve 418 ahelps prevent the cross sectional area of the elastic strand 316 fromexpanding beyond the third cross sectional area A3 of the first sleeve418 a when tension has on elastic strand 316 has been reduced. Thetendency of the elastic strand 316 to expand creates forces F(represented by dashed double arrow lines in FIG. 44B) exerted betweenelastic strand 316 and the inner perimeter of the first sleeve 418 a. Inturn, the forces F between the elastic strand 316 and the first sleeve418 a creates a frictional lock by increasing the friction forcesbetween the elastic strand 316 and the bonds 408 and portions of thefirst substrate 306 and the second substrate 308 that define the innerperimeter of the first sleeve 418 a. The increased friction forces inthe machine direction MD along the length of the elastic strand 316 inthe first sleeve 418 a holds or secures the discrete length of theelastic strand 316 in a fixed position in the first sleeve 418 atogether with the first and second substrates 306, 308.

In some configurations, no adhesive may be applied to and/or presentbetween the elastic strand 316 and the first sleeves 418 a. It is alsoto be appreciated that in some configurations, adhesive may be appliedto and/or present between the elastic strand 316 and the first sleeves418 a to help the frictional lock hold the discrete length of theelastic strand 316 in a fixed position with the first and secondsubstrates 306, 308. In some configurations, adhesive and the frictionallock in the first sleeves 418 a may share the load exerted by elasticstrand 316. In some configurations, adhesive positioned on the elasticstrand 316 may increase the coefficient of friction between the elasticstrand 316 and the first sleeve 418 a. It is to be appreciated thatvarious quantities of adhesive may be present in the first sleeve 418 a,such as for example, about 10 gsm or less.

As discussed above, second channels 522 b in the pattern roll 502 may beconfigured to create second sleeves 418 b configured to create secondsleeves 418 b that are sized to allow the elastic strands 316 to moverelative to the first and second substrates 306, 308 as the elasticstrands 316 stretch and contract along machine direction MD. The secondsleeve 418 b may also help hold or guide the elastic strands 316 indesired positions along the cross direction CD as the elastic strands316 stretch and contract along machine direction MD. For example, theelastic strand 316 shown in FIG. 43A may define a second cross sectionalarea A2 in a stretched state. The elastic strand 316 may also define afirst cross sectional area A1 in a relaxed state, wherein A2 is lessthan A1. In turn, the second sleeves 418 b may define a fourth crosssectional area A4 that may be greater than the third cross sectionalarea A3 of the first sleeves 418 a. In some configurations, A4 may begreater than A1. As such, when the elastic strand 316 contracts andexpands, no frictional bond is formed between the elastic strand and thesecond sleeves 418 b. Thus, the elastic strand 316 is allowed to moverelative to the first and second substrates 306, 308 along the machinedirection MD while also being held in a fixed cross directionalposition.

It is also to be appreciated that the elastic strands 316 herein bondedin accordance with the methods described herein may also be constructedfrom one or more filaments 406. For example, FIG. 44C shows a crosssectional view of a stretched elastic strand 316 in a sleeve 418 whereinthe elastic strand 316 comprises a plurality of individual filaments406. As shown in FIG. 44C, the elastic strand 316 may include outerfilaments 406 a surrounding an inner filament 406 b. The outer filaments406 a may define an outer perimeter of the elastic strand 316, and theouter filaments 406 a may surround the inner filament 406 b such thatthe inner filament 406 b is not in contact with the sleeve 418 when theelastic strand 316 is in a relaxed state. It is to be appreciated thatthe filaments 406 may be arranged in various positions within the sleeve418. For example, FIG. 44D shows a cross sectional view of an elasticstrand 316 in a sleeve 418 wherein the plurality of individual filaments406 together define a perimeter that is elongated along the crossdirection CD.

As previously mentioned with reference to FIG. 38 , the pattern roll 502includes a protuberance 516 that operates to intermittently sever one ormore elastic strands 316 to create deactivated regions 410 in theelastomeric laminate 302. As shown in FIGS. 41 and 42A-42C, theprotuberance 516 may extend axially along the axis of rotation 506 andmay extend radially outward from the axis of rotation 506 to a secondradial distance R2. In some configurations, R1 may be equal to orsubstantially equal to R1. And in some configurations, R2>(R1−D1) and/orR2>(R1−D2). It is to be appreciated that the pattern roll 502 mayinclude one or more protuberances 516 that may be configured in variousways with various different sizes and/or shapes. In some examples, theprotuberance 516 may be configured as a discrete member that is separatefrom the bonding elements 512 and/or bonding surfaces 510. In someexamples, the protuberance may comprise a portion of a bonding element512 and/or bonding surface 510. In some examples, the protuberance mayextend axially along the axis of rotation 506 for a distance that isequal to or less than the axial length of the pattern roll 502. Theprotuberance may also be positioned circumferentially between twodiscrete first channels 418 a and/or two discrete second channels 418 b.

As discussed above with reference to FIGS. 38 and 39 , advancing elasticstrands 316 may be joined with the first substrate 306 and the secondsubstrate 308 to form the elastomeric laminate 302. In turn, the bondapplicator 500, comprising the pattern roll 502 and the pressing surface504, applies bonds 408 that secure the elastic strands 316 between thefirst substrate 306 and the second substrate 308. In addition, the bondapplicator 500 severs one or more stretched elastic strands 316 tocreate deactivated regions 410 in the elastomeric laminate 302.

FIGS. 45A-45E provide detailed example illustrations of the elastomericlaminate 302 advancing from the nip 508 between the rotating patternroll 502 and the pressing surface 504. For the purposes of clarity, thefirst substrate 306 is not shown in the views of elastomeric laminate302 in FIGS. 45A-45E. With reference to FIGS. 38 and 45A, the first andsecond substrates 306, 308 with the stretched elastic strands 316therebetween form an elastomeric laminate 302 advancing in a machinedirection MD. The elastomeric laminate 302 is partially wrapped aroundthe pattern roll 502, wherein the stretched elastic strands 316 extendthrough discrete channels 522 in the pattern surfaces 510, such asdiscussed above with reference to FIGS. 39A, 40, and 41 . As the patternroll 502 rotates, the first substrate 306 and the second substrate 308are welded together between the bonding surfaces 510 and the pressingsurface 504 to create bonds 408 between the first and second substrates306, 308. The bonds 408 are separated from each other in the crossdirection CD by the stretched elastic strands 316 positioned inrespective discrete channels 522 to form sleeves 418 surrounding thestretched elastic strands 316. As discussed above with reference toFIGS. 41-43B, the pattern roll 502 may include first channels 522 aconfigured to create first sleeves 418 a that are sized to securediscrete lengths of the elastic strands 316 in fixed positions relativeto the first and second substrates 306, 308 with a frictional lock. Andthe second channels 522 b may be configured to create second sleeves 418b that are sized to allow the elastic strands 316 to move relative tothe first and second substrates 306, 308 as the elastic strands 316stretch and contract along machine direction MD while at the same timeholding and/or guiding the elastic strands 316 in desired positionsalong the cross direction CD. FIG. 45A illustrates an examplearrangement of first and second sleeves 418 a, 418 b along the machinedirection MD of the elastomeric laminate 302.

As discussed above with reference to FIGS. 41 and 42C, the pattern roll502 also includes one or more protuberances 516 that sever one or morestretched elastic strands 316 to create deactivated regions 410 in theelastomeric laminate 302. With reference to FIG. 45B, as the patternroll 502 continues to rotate, the first substrate 306, the secondsubstrate 308, and one or more stretched elastic strands 316 arecompressed between the pressing surface 504 and the protuberance 516 tosever the one or more stretched elastic strands 316. As shown in FIG.45B, the protuberance 516 may also comprise a bonding surface 510 thatalso welds the first and second substrates 306, 308 together with a bond408 a while also operating to sever the elastic strands 316.

As shown in FIG. 45B, upstream ends 316 a and downstream ends 316 b ofthe severed elastic strands 316 may begin to retract in opposingdirections. As previously mentioned, the first substrate 306, the secondsubstrate 308, and the stretched elastic strands 316 may be partiallywrapped onto the rotating pattern roll 502. And tension exerted on thefirst and second substrates 306, 308 and the stretched elastic strands316 forces the elastomeric laminate 302 against a portion of the patternroll 502 upon which the elastomeric laminate 302 is wrapped. As such,the tension and resulting forces causes the first and second substrates306, 308 to press against each other and against the stretched elasticstrands 316 therebetween. Thus, as the stretched elastic strands 316 aresevered, pressure exerted by the substrates 306, 308 on the elasticstrands 316 therebetween may help the ends 316 a, 316 b of the severedelastic strands 316 retract or snap back at a relatively slower and/orcontrolled rate.

As shown in FIGS. 45C and 45D, as the pattern roll 502 continues torotate, additional bonds 408 may be applied to the elastomeric laminate302 upstream of retracting upstream ends 316 a of the severed elasticstrands 316. As shown in FIG. 45E, the ends 316 a, 316 b of the elasticstrands 316 may retract to first sleeves 418 a until a frictional lockis created between the elastic strands 316 and the first sleeves 418 a.In turn, the frictional lock prevents the ends 316 a, 316 b of theelastic strands 316 from further retraction relative to the first andsecond substrates 306, 308. Retraction of the severed elastic strands316 creates a deactivated region 410 in the elastomeric laminate 302.For the purposes of clarity, dashed lines 414 are shown in FIG. 45E torepresent example boundaries between the deactivated regions 410 and theelastomeric regions 412 of the elastomeric laminate 302. Also, as shownin FIGS. 45C and 45D, the ends 316 a, 316 b of the severed elasticstrands 316 retract through the second sleeves 316 b while at the sametime being guided along the machine direction MD by the second sleeves418 b while retracting.

It is also to be appreciated that the strands 316 and/or filaments 406herein may define various different cross-sectional shapes. For example,in some configurations, strands 316 or filaments 406 may definecircular, oval, or elliptical cross sectional shapes or irregularshapes, such as dog bone and hourglass shapes.

It is to be appreciated that the bond applicator 500 herein may beconfigured in various ways with various features described herein toassemble elastomeric laminates 302. For example, as shown in FIG. 38A,the bond applicator 500 may be configured as a mechanical bonding devicethat includes an anvil 526 that defines the pressing surface 504operating in conjunction with the pattern roll 502. As such, the patternroll 502 and/or anvil 526 may be configured to apply heat and pressurein various other ways to perform the bonding and cutting operationsdescribed above, such as for example, the mechanical bonding devices andmethods disclosed in U.S. Pat. Nos. 4,854,984; 6,248,195; 8,778,127; and9,005,392; and U.S. Patent Publication Nos. 2014/0377513 A1; and2014/0377506 A1.

As discussed above, the pattern roll 502 includes a protuberance 516that engages the pressing surface 504 to intermittently sever one ormore elastic strands 316 to create deactivated regions 410 in theelastomeric laminate 302. In some configurations, the one or moreelastic strands 316 may be severed downstream of the pressing surface504. For example, as shown in FIG. 38B, the bond applicator 500 may beconfigured to include a cutting roll 528 that may include one or moreblades 530 and adapted to rotate around an axis of rotation 532. Thecutting roll 528 may also be positioned adjacent the pattern roll 502 todefine a nip 534 therebetween positioned downstream of the nip 508between the pattern roll 502 and the pressing surface 504. In operation,the elastomeric laminate 302 advances through the nip 508 between thepattern roll 502 and the pressing surface 504 to apply the bonds 408that secure the elastic strands 316 between the first substrate 306 andthe second substrate 308. However, the protuberance 516 on the patternroll 502 may be configured such that the elastomeric laminate 302advances between the protuberance 516 and the pressing surface 504without severing elastic strands 316. As such, the method and apparatusof FIG. 38B may also be adapted to create deactivated regions 410 in theelastomeric laminate 302 by severing elastic strands 316 that have beenbonded in accordance with the methods and apparatuses described abovewith reference to FIGS. 26-37 as well as other bonding methods describedherein. For example, FIGS. 50 and 51 show a pattern roll 502 withbonding surfaces 510 positioned at a first radial distance R1 from theaxis of rotation 506. The pattern roll 502 also includes a protuberance516 extending axially along the axis of rotation 506 and extendingradially outward from the axis of rotation 506 to a second radialdistance R2. As shown in FIG. 52 , the second radial distance R2 may beless than the first radial distance R1 such that the elastic strands 316are not severed between the protuberance 516 and the pressing surface504. In turn, the elastomeric laminate 302 advances from the nip 508 tothe nip 534 between the cutting roll 528 and the pattern roll 502wherein the blade 530 engages the protuberance 516 to sever one or moreelastic strands 316 to create deactivated regions 410 in the elastomericlaminate 302.

It is to be appreciated that various configurations of cutting rolls 528can be used with the apparatuses and methods herein. Such cutting rollconfigurations may include features of the cutting blades/unitsdisclosed, for example, in U.S. Pat. Nos. 5,393,360; 7,708,849;7,861,756; 7,777,094; and 8,440,043; and U.S. Patent Publication No.2013/0261589 A1, which are all incorporated by reference herein. Assuch, the cutting rolls may be configured with die knife, flexibleblade, and/or compression roll features, and may also include additionalfeatures to control knife-anvil gaps and/or force. In someconfigurations, a laser device may be utilized to cut the elasticstrands 316.

As discussed above, the pattern roll 502 may include one or moreprotuberances 516 that may be configured in various ways with variousdifferent sizes and/or shapes. For example as shown in FIG. 41A, theprotuberance 516 may be configured as one or more discrete members 536that are separate from the bonding elements 512 and/or bonding surfaces510. The discrete members 536 may also be axially offset with respect tothe channels 522, and as such, may also be configured to the bond thefirst and second substrates 306, 308 together while simultaneouslysevering the elastic strands 316. As shown in FIG. 46A, the discretemembers 536 may create discrete bonds 408 a shaped and arranged in apattern corresponding with the shapes of the discrete members 536. Inanother configuration shown in FIG. 46B, the protuberance 516 and/or thediscrete members 536 may be configured to cut the elastic strands 316into one or more discrete lengths or pieces 316 c in the deactivatedregion 410.

As previously mentioned, the first substrate and second substrate 306,308 herein may be defined by two discrete substrates or may be definedby folded portions of a single substrate. In addition, the secondmetering device 312 may also be configured as the bond applicator 500.For example, as shown in FIG. 47 , the first substrate 306 may advanceat speed S1 to the first roller 324 where the first substrate 306partially wraps around the pattern roll 502. While partially wrappedaround the pattern roll 502, the first substrate 306 is combined withthe elastic strands 316. As the beam 314 rotates, the elastic strands316 advance from the beam 314 at a speed S2 with the elastic strands 316being spaced apart from each other in the cross direction CD. From thebeam 314, elastic strands 316 advance to the pattern roll 502 and arepositioned on the second surface 340 of the first substrate 306. Asshown in FIGS. 47 and 48 , a folding device 538 may operate to fold afirst portion 306 a onto a second portion 306 b of the first substrate306 with the elastic strands 316 positioned between the first and secondportions 306 a, 306 b to create the elastomeric laminate 302. As shownin FIGS. 47 and 49 , the pressing surface 504 may be configured to applythe bonds 408 and intermittently sever one or more elastic strands 316before elastomeric laminate 302 advances from the pattern roll 502.

Some methods and apparatuses according to the present disclosure may beconfigured with a first plurality of elastic strands wound onto a firstbeam and a second plurality of elastic strands wound onto a second beam.During assembly of an elastomeric laminate, a first substrate isadvanced onto the outer circumferential surface of the roller that isrotating about a first axis of rotation extending in a cross direction.The first beam is rotated to unwind the first plurality of elasticstrands from the first beam in the machine direction. The firstplurality of elastic strands may be stretched in the machine directionwhile advancing from the first beam onto the first substrate. A secondsubstrate advances onto the first substrate such that the firstplurality of elastic strands are positioned between the first substrateand the second substrate to form the elastomeric laminate. Before thefirst plurality of elastic strands are completely unwound from the firstbeam, the second beam is rotated to unwind the second plurality ofelastic strands from the second beam in the machine direction, whereinthe second plurality of elastic strands are separated from each other inthe cross direction. The second plurality of elastic strands areadvanced in the machine direction from the second beam to between thefirst substrate and the second substrate such that the first andplurality of elastic strands are positioned between the first and secondsubstrates. Subsequently, the advancement of the first plurality ofelastic strands from the first beam is discontinued. As such, theelastomeric laminate assembly process may continue uninterrupted whileswitching from an initially utilized elastic material drawn from thefirst beam to a subsequently utilized elastic material drawn from thesecond beam.

For example, FIGS. 53-70 show schematic views of converting apparatuses300 adapted to manufacture elastomeric laminates 302. As described inmore detail below, the converting apparatuses 300 shown in FIGS. 53-70operate to advance a continuous length of elastic material 304, acontinuous length of a first substrate 306, and a continuous length of asecond substrate 308 along a machine direction MD. It is also to beappreciated that in some configurations, the first substrate and secondsubstrate 306, 308 herein may be defined by two discrete substrates ormay be defined by folded portions of a single substrate. The apparatus300 stretches the elastic material 304 and joins the stretched elasticmaterial 304 with the first and second substrates 306, 308 to produce anelastomeric laminate 302. Although the elastic material 304 isillustrated and referred to herein as strands, it is to be appreciatedthat elastic material 304 may include one or more continuous lengths ofelastic strands, ribbons, and/or films.

As discussed in more detail below, the converting apparatuses 300 mayinclude metering devices arranged along a process machine direction MD,wherein the metering devices may be configured to stretch the advancingelastic material and/or join stretch elastic material with one or moreadvancing substrates. In some configurations, a metering device maycomprise a beam of elastic strands wound thereon. During operation,elastic material may advance in a machine direction from a firstrotating beam to a downstream metering device to be joined with one ormore advancing substrates. Before the elastic material is completelydrawn from or removed from the first beam, elastic material may also beadvanced in the machine direction from a second rotating beam to thedownstream metering device to be joined with one or more advancingsubstrates. Subsequently, advancement of the elastic material from thefirst beam to the downstream metering device may be discontinued. Assuch, the elastomeric laminate assembly process continues uninterruptedwhile replacing elastic material unwound from the first beam withelastic material unwound from the second beam. Thus, the empty firstbeam may be replaced with another beam with elastic material woundthereon without interrupting and/or stopping the assembly of theelastomeric laminate.

As shown in FIGS. 53 and 55 , a converting apparatus 300 for producingan elastomeric laminate 302 may include a first metering device 310, asecond metering device 312, and a third metering device 422. The firstmetering device may be configured as a first beam 314 a with a firstplurality of elastic strands 316 a wound thereon, and the third meteringdevice is configured as a second beam 314 b with a second plurality ofelastic strands 316 b wound thereon. During operation, the firstplurality of elastic strands 316 a advance in the machine direction MDfrom the first beam 314 a to the second metering device 312. Inaddition, the first plurality of elastic strands 316 a may be stretchedalong the machine direction MD between the first beam 314 a and thesecond metering device 312. The stretched first elastic strands 316 aare also joined with a first substrate 306 and a second substrate 308 atthe second metering device 312 to produce an elastomeric laminate 302.As discussed in more detail below, once the first beam 314 a is empty ornearly depleted of first elastic strands 316 a, the second plurality ofelastic strands 316 b can be introduced into the assembly operation asreplacements for the first plurality of elastic stands 316 a withouthaving to stop the assembly operation. FIGS. 53 and 54 show anarrangement of first and second rollers 324, 330 and associated featuresdescribed above with reference to FIGS. 5 and 6 that may be utilized tocombine elastic strands 316 and first and second substrates 306, 308 toproduce a continuous length of elastomeric laminate 302.

With continued reference to FIGS. 53 and 54 , the first beam 314 aincludes the first plurality of elastic strands 316 a wound thereon, andthe first beam 314 a is rotatable about a first beam rotation axis 346a. In some configurations, the first beam rotation axis 346 a may extendin the cross direction CD. As the first beam 314 a rotates, the firstplurality of elastic strands 316 a advance from the first beam 314 a ata speed S2 with the first elastic strands 316 a being spaced apart fromeach other in the cross direction CD. From the first beam 314 a, thefirst plurality of elastic strands 316 a advances in the machinedirection MD to the nip 336. In some configurations, the speed S2 isless than the speed S1, and as such, the first plurality of elasticstrands 316 a are stretched in the machine direction MD. In turn, thestretched first elastic strands 316 a advance through the nip 336between the first and second substrates 306, 308 such that the firstelastic strands 316 a are joined with the second surface 340 of thefirst substrate 306 and the first surface 342 of the second substrate308 to produce a continuous length of elastomeric laminate 302. As shownin FIG. 53 , the first substrate 306 may advance past an adhesiveapplicator device 424 that applies adhesive 426 to the second surface340 of the first substrate 306 before advancing to the nip 336. It is tobe appreciated that the adhesive 426 may be applied to the firstsubstrate 306 upstream of the first roller 324 and/or while the firstsubstrate 306 is partially wrapped around the outer circumferentialsurface 326 of the first roller 324. It is to be appreciated thatadhesive may be applied to the first elastic strands 316 a before and/orwhile being joined with first substrate 306 and second substrate 308. Inaddition, it is to be appreciated that adhesive may be applied to thefirst surface 342 of the second substrate 308 before or while beingjoined with the first elastic strands 316 a and the first substrate 306.It is also to be appreciated that the elastic strands 316 may be bondedwith the first substrate 306 and/or second substrate 308 with thevarious methods and apparatuses described herein and combinationsthereof.

As previously discussed, the apparatus 300 includes the second pluralityof elastic strands 316 b configured to replace the first plurality ofelastic stands 316 a once the first beam 314 a is completely depleted ornearly depleted of first elastic strands 316 a. As shown in FIGS. 53 and54 , the second beam 314 b includes the second plurality of elasticstrands 316 b wound thereon, and the second beam 314 b is rotatableabout a second beam rotation axis 346 b. In some configurations, thesecond beam rotation axis 346 b may extend in the cross direction CD. Asthe second beam 314 b rotates, the second plurality of elastic strands316 b advance from the second beam 314 b at a speed S2 with the secondelastic strands 316 b being spaced apart from each other in the crossdirection CD. When introducing the second elastic strands 316 b into theassembly operation, the second plurality of elastic strands 316 b mayfirst be connected with a splicer member 430. As shown in FIG. 55 , thesplicer member 430 may be connected adjacent leading ends 432 of thesecond elastic strands 316 b. In turn, the splicer member 430 and thesecond elastic strands 316 b may be connected with the first pluralityof elastic strands 316 a that are advancing from the first beam 314 a tothe nip 336 as shown in FIG. 56 . As shown in FIGS. 57 and 58 , thesplicer member 430 and the leading ends 432 of the second plurality ofelastic strands 316 b advance in the machine direction MD and arepositioned between the first and second substrates 306, 308 along withthe first plurality of elastic strands 316 a. Once the second elasticstrands 316 b are combined with the first substrate 306 and/or secondsubstrate 308, advancement of the first plurality of elastic strands 316a from the first beam 314 a may be discontinued. In some instances,advancement of the first plurality of elastic strands 316 a from thefirst beam 314 a may be discontinued as a result of the first elasticstrands 316 a being completely unwound from the first beam 314 a suchthat trailing ends 434 of the first elastic strands 316 a advancethrough the nip 336 such as shown in FIGS. 57 and 58 . In someconfigurations, the first elastic strands 316 a may be cut todiscontinue advancement from the first beam 314 a.

As shown in FIGS. 59 and 60 , the apparatus 300 continues to operate toassemble the elastomeric laminate 302 with the second plurality ofelastics 316 b on the second beam 314 b. As the second beam 314 brotates, the second plurality of elastic strands 316 b advance from thesecond beam 314 b at a speed S2 with the second elastic strands 316 bbeing spaced apart from each other in the cross direction CD. From thesecond beam 314 b, the second plurality of elastic strands 316 badvances in the machine direction MD to the nip 336. In someconfigurations, the speed S2 is less than the speed S1, and as such, thesecond plurality of elastic strands 316 b are stretched in the machinedirection MD. In turn, the stretched second elastic strands 316 badvance through the nip 336 between the first and second substrates 306,308 such that the second elastic strands 316 b are joined with thesecond surface 340 of the first substrate 306 and the first surface 342of the second substrate 308 to produce the continuous length ofelastomeric laminate 302. Thus, the second plurality of elastic strands316 b can be introduced into the assembly operation as replacements forthe first plurality of elastic stands 316 a without having to stoprotation of the first beam 314 a and without having to stop theelastomeric laminate 302 assembly operation. In turn, the empty firstbeam 314 a, such as shown in FIG. 4 , can be replaced with a beam havinga plurality of elastics wound thereon positioned to replace the secondplurality of elastics 316 b once depleted from the second beam 314 b.

Although FIG. 54 shows nine elastic strands 316 a advancing from thefirst beam 314 a, it is to be appreciated that the apparatuses hereinmay be configured such that more or less than nine elastic strands 316 aadvance from the first beam 314 a. And although FIG. 55 shows nineelastic strands 316 b advancing from the second beam 314 b, it is to beappreciated that the apparatuses herein may be configured such that moreor less than nine elastic strands 316 b advance from the second beam 314b.

It is to be appreciated that the apparatus 300 can be configured tooperate in various ways to advance the leading ends 432 of the secondplurality of elastics 316 b between the first and second substrates 306,308. For example, the splicer member 430 discussed above with referenceto FIG. 55 may include one or more tacky surfaces 436 adapted to adhereto the second plurality of elastic strands 316 b. In addition, the oneor more tacky surfaces 436 also adhere the splicer member 430 with theadvancing first plurality of elastic strands 316 a as described abovewith reference to FIGS. 56-58 . It is also to be appreciated that thesplicer member 430 may be connected with the first elastic strands 316 awith adhesive applied to the first elastic strands 316 a upstream of thenip 336. It is also to be appreciated that in some configurations of theapparatus 300, the second elastic strands 316 b may be introduced intothe assembly operation without having to connect the second elasticstrands 316 b with a splicer member 430.

In some configurations, as opposed to being connected with the firstelastic strands 316 a, the splicer member 430 and/or second elasticstrands 316 b may be connected with the first substrate 306 or thesecond substrate 308 upstream of the nip 336. For example, as shown inFIG. 61 , after second elastic strands 316 b are connected with thesplicer member 430, the splicer member 430 may be connected with thesecond surface 340 of the first substrate 306. As discussed above, thesplicer member 430 may include a tacky surface 436 that adheres to thefirst substrate 306 and/or may be adhered to the first substrate withadhesive 426. Once the splicer member 430 is connected with the firstsubstrate 306, the splicer member 430 and second elastic strands 316 badvance along with the first substrate 306 through the nip 336.

It is to be appreciated that the apparatuses 300 herein may beconfigured in various ways. For example, in another configuration of theapparatus 300 shown in FIG. 62 , the second roller 330 may be positioneddownstream from the first roller 324. As such, the first roller 324 maybe configured as the second metering device 312 and the second roller330 may be configured as a fourth metering device 438. As shown in FIG.62 , the first substrate 306 advances at speed S1 to the first roller324 where the first substrate 306 partially wraps around the outercircumferential surface 326 of the first roller 324 and advances fromthe first roller to the second roller 330 to be combined with secondsubstrate 308. As the first beam 314 a rotates, the first plurality ofelastic strands 316 a advance from the first beam 314 a at a speed S2with the first elastic strands 316 a being spaced apart from each otherin the cross direction CD. From the first beam 314 a, the firstplurality of elastic strands 316 a advances in the machine direction MDto the first roller 324 and are positioned on the second surface 340 ofthe first substrate 306. In some configurations, the speed S2 is lessthan the speed S1, and as such, the first plurality of elastic strands316 a are stretched in the machine direction MD.

With continued reference to FIG. 62 , the first substrate 306 and thefirst plurality of elastic strands 316 a advance from the outercircumferential surface 326 of the first roller 324 to the second roller330. In addition, the second substrate 308 advances at speed S1 to thesecond roller 330 where the second substrate 308 partially wraps aroundthe outer circumferential surface 332 of the second roller 330. In turn,the combined first substrate 306 and the stretched first elastic strands316 a advance from first roller 324 to the second roller 330 and arecombined with the second substrate 308 such that the first elasticstrands 316 a are joined with the second surface 340 of the firstsubstrate 306 and the first surface 342 of the second substrate 308 toproduce a continuous length of elastomeric laminate 302. As discussedabove, the first substrate 306 may advance past an adhesive applicatordevice 424 that applies adhesive 426 to the second surface 340 of thefirst substrate 306 while advancing to the first roller 324. It is to beappreciated that the adhesive 426 may be applied to the first substrate306 while the first substrate 306 is partially wrapped around the outercircumferential surface 326 of the first roller 324. It is to beappreciated that adhesive may also be applied to the first elasticstrands 316 a before and/or while being joined with first substrate 306and second substrate 308. In addition, it is to be appreciated thatadhesive may be applied to the first surface 342 of the second substrate308 before or while being joined with the first elastic strands 316 aand first substrate 306.

As previously discussed, the apparatus 300 includes the second pluralityof elastic strands 316 b configured to replace the first plurality ofelastic stands 316 a once the first beam 314 a is completely depleted ornearly depleted of first elastic strands 316 a. As shown in FIGS. 62 and63 , as the second beam 314 b rotates, the second plurality of elasticstrands 316 b advance from the second beam 314 b at a speed S2 with thesecond elastic strands 316 b being spaced apart from each other in thecross direction CD. As discussed above, the second plurality of elasticstrands 316 b may first be connected with a splicer member 430. In turn,the splicer member 430 and the second elastic strands 316 b may beconnected with the first plurality of elastic strands 316 a that areadvancing from the first beam 314 a to the first roller 324, as shown inFIG. 63 . As shown in FIG. 63 , the splicer member 430 and the leadingends 432 of the second plurality of elastic strands 316 b advance in themachine direction MD and are positioned on the second surface 340 of thefirst substrate 306 on the first roller 324. From the first roller 324,the combined first substrate 306, first elastic strands 316 a, secondelastic strands 316 b, and splicer member 430 advance to the secondroller 330 and are positioned between the first and second substrates306, 308. Once the second elastic strands 316 b are combined with thefirst substrate 306 and/or second substrate 308, advancement of thefirst plurality of elastic strands 316 a from the first beam 314 a maybe discontinued wherein trailing ends 434 of the first elastic strands316 a advance downstream to the first and second rollers 324, 330, suchas shown in FIG. 64 .

As shown in FIGS. 64 and 65 , the apparatus 300 continues to operate toassemble the elastomeric laminate 302 with the second plurality ofelastic strands 316 b advancing from the second beam 314 b. As thesecond beam 314 b rotates, the second plurality of elastic strands 316 badvance from the second beam 314 b at a speed S2 with the secondelastics strands 316 b being spaced apart from each other in the crossdirection CD. From the second beam 314 b, the second plurality ofelastic strands 316 b advances in the machine direction MD to the firstroller 324 and are positioned on the second surface 340 of the firstsubstrate 306. In some configurations, the speed S2 is less than thespeed S1, and as such, the second plurality of elastic strands 316 b arestretched in the machine direction MD. In turn, the stretched secondelastic strands 316 b advance from the first roller 324 to the secondroller 330 such that the second elastic strands 316 b are joined withthe second surface 340 of the first substrate 306 and the first surface342 of the second substrate 308 to produce the continuous length ofelastomeric laminate 302.

As discussed above and as shown in FIG. 66 , as opposed to beingconnected with the first elastic strands 316 a, the splicer member 430and the second elastic strands 316 b may be connected with the firstsubstrate 306 upstream of the first roller 306. Once the splicer member430 is connected with the first substrate 306, the splicer member 430and second elastic strands 316 b advance along with the first substrate306 to the first roller 306 and the second roller 330 to assemble theelastomeric laminate 302.

As previously mentioned, the second elastic strands 316 b may beintroduced into the assembly operation without having to connect thesecond elastic strands 316 b with a splicer member 430. Thus, the secondelastic strands 316 b may be connected directly with the first substrate306. It is also to be appreciated that the splicer member 430 and/or thesecond elastic strands 316 b may be connected with the first substrate306 while partially wrapped around the outer circumferential surface 326of the first roller 306. It is also to be appreciated that the splicermember 430 and/or the second elastic strands 316 b may be connected withthe second substrate 308 upstream of the second roller 330 or whilepartially wrapped around the outer circumferential surface 332 of thesecond roller 330.

In another configuration shown in FIG. 67 , the apparatus 300 may beconfigured with only the first roller 324 and without a second roller330. As such, the first roller 324 may be configured as the secondmetering device 312. As shown in FIG. 67 , the first substrate 306advances at speed S1 to the first roller 324 where the first substrate306 partially wraps around the outer circumferential surface 326 of thefirst roller 324. While partially wrapped around the outercircumferential surface 326 of the first roller 324, the first substrate306 is combined with the first elastic strands 316 a and the secondsubstrate 308. As the first beam 314 a rotates, the first plurality ofelastic strands 316 a advance from the first beam 314 a at a speed S2with the first elastic strands 316 a being spaced apart from each otherin the cross direction CD. From the first beam 314 a, the firstplurality of elastic strands 316 a advances in the machine direction MDto the first roller 324 and are positioned on the second surface 340 ofthe first substrate 306. In some configurations, the speed S2 is lessthan the speed S1, and as such, the first plurality of elastic strands316 a are stretched in the machine direction MD.

With continued reference to FIG. 67 , the second substrate 308 advancesat speed S1 to the first roller 324 and partially wraps around the outercircumferential surface 326 of the first roller 324. In turn, the secondsubstrate 308 is combined with the first substrate 306 and the stretchedfirst elastic strands 316 a while on the first roller 324 such that thefirst elastic strands 316 a are joined with the second surface 340 ofthe first substrate 306 and the first surface 342 of the secondsubstrate 308 to produce a continuous length of elastomeric laminate302. As discussed above, the first substrate 306 may advance past anadhesive applicator device 424 that applies adhesive 426 to the secondsurface 340 of the first substrate 306 while advancing to the firstroller 324. It is to be appreciated that the adhesive 426 may be appliedto the first substrate 306 while the first substrate 306 is partiallywrapped around the outer circumferential surface 326 of the first roller324. It is to be appreciated that adhesive may also be applied to thefirst elastic strands 316 a before and/or while being joined with firstsubstrate 306 and second substrate 308. In addition, it is to beappreciated that adhesive may be applied to the first surface 342 of thesecond substrate 308 before or while being joined with the first elasticstrands 316 a and first substrate 306.

As previously discussed, the apparatus 300 includes the second pluralityof elastic strands 316 b configured to replace the first plurality ofelastic stands 316 a once the first beam 314 a is completely depleted ornearly depleted of first elastic strands 316 a. As shown in FIGS. 67 and68 , as the second beam 314 b rotates, the second plurality of elasticstrands 316 b advance from the second beam 314 b at a speed S2 with thesecond elastic strands 316 b being spaced apart from each other in thecross direction CD. In turn, leading ends 432 of the second plurality ofelastic strands 316 b may be advanced onto the first roller 324 andbetween first substrate 306 and the second substrate 308. As such, thesecond plurality of elastic strands 316 b are positioned in between thesecond surface 340 of the first substrate 306 and the first surface 342of the second substrate 308 such that the first plurality of elasticstrands 316 a, the second plurality of elastic strands 316 b, and thefirst substrate 306 are positioned between the second substrate 308 andthe outer circumferential surface 326 of the first roller 324. Asdiscussed above, the second plurality of elastic strands 316 b may alsobe first connected with a splicer member 430. Thus, it is to beappreciated that the splicer member 430 and/or the second elasticstrands 316 b may be connected with the first plurality of elasticstrands 316 a, the first substrate 306, or second substrate 308. Asshown in FIGS. 67 and 68 , the leading ends 432 of the second pluralityof elastic strands 316 b advance in the machine direction MD and arepositioned on the second surface 340 of the first substrate 306 on thefirst roller 324. And the second substrate 306 advances to the firstroller 324 to be combined with first substrate 306, first elasticstrands 316 a, and second elastic strands 316 b to form the elastomericlaminate 302. Once the second elastic strands 316 b are combined withthe first substrate 306 and/or second substrate 308, advancement of thefirst plurality of elastic strands 316 a from the first beam 314 a maybe discontinued wherein trailing ends 434 of the first elastic strands316 a advance downstream to the first roller 324, such as shown in FIG.69 .

As shown in FIGS. 69 and 70 , the apparatus 300 continues to operate toassemble the elastomeric laminate 302 with the second plurality ofelastics 316 b advancing from the second beam 314 b. As the second beam314 b rotates, the second plurality of elastic strands 316 b advancefrom the second beam 314 b at a speed S2 with the second elastic strands316 b being spaced apart from each other in the cross direction CD. Fromthe second beam 314 b, the second plurality of elastic strands 316 badvances in the machine direction MD to the first roller 324 and arepositioned on the second surface 340 of the first substrate 306. In someconfigurations, the speed S2 is less than the speed S1, and as such, thesecond plurality of elastic strands 316 b are stretched in the machinedirection MD. In turn, the stretched second elastic strands 316 b arejoined with the second surface 340 of the first substrate 306 and thefirst surface 342 of the second substrate 308 to produce the continuouslength of elastomeric laminate 302 that advances from the first roller324.

It is to be appreciated that in the various process configurationsdiscussed above, the second plurality of elastic strands 316 b may befirst connected with a splicer member 430 before advancing the elasticstrands 316 b in the assembly process. It is also to be appreciated thatin the various process configurations discussed above, the secondplurality of elastic strands 316 b may be advanced directly into theassembly process without connecting the stands 316 b to a splicermember. In some configurations, the second plurality of elastic strands316 b may be connected or tied to each other with a knot beforeadvancing into the assembly process. In some configurations, the firstand/or second substrate may have an electrostatic charge that attractsthe strands 316 b to the substrates before advancing into assemblyprocess. Further, in some configurations, strands 316 b may be directedinto the assembly process by air flow, such as provided from a fanand/or a vacuum system.

It is to be appreciated that a control system and/or an inspectionsystem may be utilized to control various aspects of the splicingoperations discussed herein. For example, as previously mentioned, thefirst beam 314 a and the second beam 314 b may be connected with one ormore motors, such as servo motors, to drive and control the rotation ofthe beams 314 a, 314 b. As such, a control system may operate to controlthe acceleration and/or deceleration of the first and/or second beams314 a, 314 b during the splicing operation to achieve and/or maintainthe desired tension in the elastic strands. In some configurations, theelastic strands may be advanced from the beams 314 a, 314 b through aseries of dancer rolls to help maintain desired tensions in the elasticstrands during splicing operations. As previously mentioned, theelastomeric laminate 302 may also be subject to additional convertingprocesses. Such additional converting processes may incorporate theelastomeric laminate 302 into discrete absorbent articles 100. As such,in some embodiments, an inspection system may be configured to detectand/or track a defective length of the elastomeric laminate 302. Withreference to FIG. 58 , a defective length of elastomeric laminate 302may be defined by a length of elastomeric laminate 302 that includesboth the first elastic strands 316 a and the second elastic strands 316b positioned together between the first and second substrates 306, 308.A defective length of elastomeric laminate 302 may also be defined by alength of elastomeric laminate 302 that includes the splicer member 430,leading ends 432 of the second elastic strands 316 b, and/or thetrailing ends 434 of the first elastic strands 316 a. The inspectionsystem may also correlate inspection results and measurements from thedefect length of the elastomeric laminate 302 with absorbent articles100 made therefrom. In turn, the inspection system may be used tocontrol a reject system on a converting process of absorbent articles,wherein absorbent articles manufactured with portions of the defectivelength of elastomeric laminate 302 are rejected. In some configurations,defective articles may be subject to the rejection system and removedfrom the assembly process. Absorbent articles 100 that are not deemed tobe defective may be subject to further processing steps, such as foldingand packaging. In some configurations, an inspection system may beconfigured to detect a broken elastic strand advancing from a first beam314 a. Upon detection of a broken elastic strand, the inspection systemmay activate a splicing operation, such as described above, to place asecond beam 314 b into service and remove the first beam 314 a fromservice. In some configurations, an inspection and/or a control systemmay operate to control the timing and placement of the splicer member430 into the assembly operation, such as in the nip 336 shown in FIG. 54, which may help an inspection system to more accurately track asplicing event. It is to be appreciated that such an inspection systemmay be configured in various ways, such as disclosed in U.S. PatentPublication No. 2013/0199696 A1.

It is to be appreciated that various operational abnormalities mayresult while elastic strands 316 are advancing from a beam 314 duringassembly operations disclosed herein. For example, breakouts may occurduring assembly operations, wherein one or more elastic strands 316unintentionally breaks while advancing from the beam 314 during assemblyof the elastomeric laminate 302. As such, the methods and apparatusesherein may include various devices to help isolate broken elasticstrands, such as disclosed in U.S. Patent Publication Nos. 2014/0209652A1 and 2014/0224855 A1. In some instances, the methods and apparatusesmay include a snare member adjacent the beam 314 or other assemblycomponents to help isolate broken elastics strands, such as disclosed inU.S. Patent Publication No. 2015/0090393 A1. The apparatuses and methodsherein may also be configured with a two-step elastic strand 316straining process, wherein the elastic strands 316 advance from the beam314 and through a nip and drive roll before advancing in the machinedirection to be combined with the first and second substrates 306, 308.Such a nip and drive roll arrangement may help isolate broken elasticstrands from the beam 314. The apparatuses and methods herein may alsobe configured with devices and other arrangements to help automaticallyrethread broken elastic strands 316, such as disclosed in U.S. PatentPublication Nos. 2013/0199707 A1 and 2013/0199696 A1. In someconfigurations, beams 314 may be wound with elastic strands 316 havingpieces of tape extending across the strands, wherein the tape pieces areintermittently spaced apart along the machine direction. As such, thetape pieces may help in locating the end of a broken strand in the eventof a breakout.

It is to be appreciated that the elastomeric laminates 302 assembledwith the methods and apparatuses herein may be subjected to variousother manufacturing transformations, such as cutting and slitting,depending on a particular absorbent article assembly process. Forexample, a continuous elastomeric laminate 302 may advance to a slittingoperation, wherein the elastomeric laminate 302 is slit and separatedalong the machine direction MD into a first continuous elastomericlaminate and a second continuous elastomeric laminate. It is to beappreciated that the elastomeric laminate 302 may be slit with a shearslitting operation or a crush slit operation. In a crush slit operation,the first substrate 306 and the second substrate 308 may be bondedtogether during the slitting operation. In some operations, the firstand second substrates 306, 308 of an elastomeric laminate 302 may bebonded together along edges of the elastomeric laminate 302. Forexample, in some operations, edges of the first substrate 306 may befolded over opposing edge portions of the second substrate 308 to createsealed edges of the elastomeric laminate 302. It is to be appreciatedthat heat, pressure, adhesive, and/or ultrasonic bonding processes maybe used to fixate such folded portions of the substrates. In someconfigurations, the locations of elastic strands 316 relative to sideedges of elastic laminates 302 may be adjusted to change corrugationpatterns along the side edges in desired manners. The elastomericlaminates 302 herein may be subject to additional operations to helpprovide aesthetic benefits, such as relatively more homogenous and/orconsistent widths along the machine direction. For example, theelastomeric laminates 302 may be subject to cross directional spreadingoperations that may be executed after the elastomeric laminate has atleast partially relaxed.

Every document cited herein, including any cross referenced or relatedpatent or application and any patent application or patent to which thisapplication claims priority or benefit thereof, is hereby incorporatedherein by reference in its entirety unless expressly excluded orotherwise limited. The citation of any document is not an admission thatit is prior art with respect to any invention disclosed or claimedherein or that it alone, or in any combination with any other referenceor references, teaches, suggests or discloses any such invention.Further, to the extent that any meaning or definition of a term in thisdocument conflicts with any meaning or definition of the same term in adocument incorporated by reference, the meaning or definition assignedto that term in this document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A method for making absorbent articles, themethod comprising steps of: providing first elastic strands wound ontobeams, wherein each beam comprises a mandrel core, and wherein the firstelastic strands comprise a first decitex; rotating the mandrel cores tounwind the first elastic strands from the mandrel cores; advancing thefirst elastic strands from the rotating mandrel cores; stretching thefirst elastic strands; and providing second elastic strands, wherein thesecond elastic strands comprise a second decitex, and wherein the seconddecitex is greater than the first decitex; unwinding the second elasticstrands from an overend unwinding device; stretching the second elasticstrands; bonding the stretched first and second elastic strands betweena first substrate and a second substrate to form an elastomeric laminatecomprising different stretch characteristics in different regions in theelastomeric laminate, wherein the first elastic strands are bonded witha first bond applicator configured to apply adhesive or mechanical bondsand wherein the second elastic strands are bonded with a second bondapplicator configured to apply adhesive bonds; and cutting the firstelastic strands to create deactivated regions in the elastomericlaminate.
 2. The method of claim 1, wherein the first substrate and thesecond substrate comprise nonwovens.
 3. The method of claim 1, furthercomprising a step of converting the elastomeric laminate into an elasticbelt for a diaper.
 4. The method of claim 1, further comprising a stepof converting the elastomeric laminate into an elastic leg cuff for adiaper.
 5. The method of claim 1, wherein the first elastic strandscomprise a spin finish.
 6. The method of claim 5, further comprising astep of removing a portion of the spin finish.
 7. The method of claim 1,further comprising a step of applying adhesive to at least one of thefirst elastic strands, the first substrate, and the second substrate. 8.The method of claim 1, further comprising a step of advancing the firstsubstrate, the second substrate, and the first elastic strands betweenan ultrasonic horn and an anvil.
 9. The method of claim 1, furthercomprising a step of bonding absorbent chassis with the deactivatedregions.
 10. The method of claim 1, further comprising a step ofunwinding at least one first elastic strand from at least one mandrelcore.
 11. The method of claim 1, wherein the first substrate comprises afirst nonwoven and the second substrate comprises a second nonwoven, andwherein the first decitex is less than about
 100. 12. The method ofclaim 1, wherein further comprising a step of spacing the first elasticstrands apart from each other by about 0.5 mm to about 4 mm.
 13. Themethod of claim 1, wherein the first elastic strands comprise about 200to about 1000 elastic strands.